Table of Contents
- How Do Roller Coasters Work?
- Parts of a Roller Coaster
- Roller Coaster Safety
- Roller Coaster Launch Systems
- Pneumatic Vs. Hydraulic Vs. Electromagnetic Launch Systems
- How to Choose the Best System for a Roller Coaster
- Avoiding Hydraulic Cylinder Failure
- Choose the Right Hydraulic System for Roller Coasters
Mechanical systems in roller coasters allow riders to have a good time while keeping them safe, so choosing the right one for your ride is an important decision. These systems launch train cars, allow them to stop, and control numerous types of safety equipment. In the case of roller coasters you need a system that will function safely and effectively in the ride design.
In choosing what mechanism will work best for your ride, it is helpful to understand the role of hydraulic systems in roller coasters and to be knowledgeable of other available systems and how they function. It is also useful to know the other parts of a roller coaster and how they work together as a whole.
How Do Roller Coasters Work?
The simple answer to how roller coasters work is physics, along with some mechanical systems, of course. Typically, once a roller coaster is launched, certain forces keep it moving, such as:
- Gravity
- Inertia
- Centripetal forces
Features such as hills, turns, and corkscrews use physical forces applied to roller coasters to send riders on an exciting journey. Natural forces on roller coasters help slow them down to build riders' tension, then send them gliding down the tracks. In those cases, roller coasters use potential and kinetic energy to keep moving. Potential energy builds up as a car climbs the track, and it is converted to kinetic energy as it glides down hills. These forces on a roller coaster mean that the train itself does not need an engine to run.
However, engineers must harness these forces in safe ways. A roller coaster will maintain speed or accelerate down hills and around curves depending on its design. Going up hills decreases the
speed, causing acceleration to fluctuate. These fluctuations make a ride both exciting and safe, since the car should not pass certain speeds while heading into turns or climbing hills. In those cases, the design is crucial, but so are the parts of a roller coaster. These particular parts of a roller coaster function to keep riders safe on their journey.
Parts of a Roller Coaster
The construction of a roller coaster can vary depending on which type it is. There are steel and wooden roller coasters which feature different elements throughout the ride depending on the design. Inverted or suspended rides have the car riding below the tracks, which requires a different type of train and harness setup. These various roller coaster designs still rely on physics and mechanical systems to keep them moving.
Under the train car and the track, roller coasters are complex mechanical systems. The car relies on other equipment and forces to keep it moving since it does not have its own engine. Those parts of a roller coaster include:
- Launch system: A launch system sets everything in motion. It is typically under the roller coaster train where the ride begins at the loading platform. There are a variety of launch mechanisms out there such as those that use hydraulics, pneumatics, electromagnets, etc.
- Chain lift: As riders approach that thrilling hill, one or several chains begin pulling the car. Gears at the top and bottom of the hill wind the chain as a motor turns the bottom gear. The chain lift is one of the essential components of a roller coaster since it helps get the ride going. If a design incorporates more than one large hill, it may use multiple chain lifts.
- Block brakes: The ride has to stop at some point, which is where brakes come in. Block brakes appear wherever the ride terminates to allow riders a safe exit.
- Trim brakes: Sometimes, roller coasters must slow down or stop during certain points of the journey. Slowing down using trim brakes may build suspense before a drop or safely slow riders down before they build up too much speed. In an emergency, trim brakes can bring the ride to a stop as well.
- Computers: Today's technology reduces the risk for roller coaster riders caused by possible human error. Computers are especially vital on rides which have more than one train on the tracks at once. The computer ensures that there is adequate space between each car to avoid potential accidents. Computers also control certain mechanical equipment, especially in the launch phase.
While those are the more mechanical aspects of a roller coaster, there are more straightforward parts that passengers see and use as they ride. Other parts of a roller coaster include safety features, which vary depending on the type of ride.
Roller Coaster Safety
Many components listed above serve to keep riders safe, but passengers do not interact with those components. Instead, they see safety features like harnesses and seat belts. These keep riders secure in their seats at launch and throughout the journey until they exit the ride.
The restraint bars on a roller coaster keep riders secure. Whether they are lap or shoulder bars, they need a reliable mechanism to lock them in place and unlock them once the ride is over. Roller coaster safety features may incorporate:
- Mechanical systems
- Hydraulic systems
- A combination of mechanical and hydraulic technologies
These systems lower and raise safety bars, so they must function well regardless of how many safety mechanisms a roller coaster uses. Depending on the construction of the ride, a car may have multiple rider safety devices. Roller coasters with extreme twists and turns or upside-down loops require more secure harnesses. If there is any risk of lifting riders out of their seat, shoulder harnesses are the right choice. A ride will also need secure harnesses and bars if a roller coaster has a rapid and powerful launch.
Roller Coaster Launch Systems
Launching is one of the most thrilling parts of a roller coaster ride. Launch systems give riders a boost before the rest of their exciting journey. There is not just one type of roller coaster launch system, since different rides require different launch equipment. The right system for a given coaster depends on how fast the ride launches passengers, the amount of space there is for the equipment, and other factors. Different types of launch equipment include:
- Electromagnets
- Hydraulics
- Pneumatics
- Flywheels
- Catapults
- Friction wheels
The type of system describes the mechanical process or component that launches the train car. Every system operates differently with varying results. The last three systems — flywheel, catapult and friction wheel— are the least common varieties of roller coaster launch systems. They are less-common choices because they tend to use more energy than the other three options. They also operate significantly different:
- Flywheel: A flywheel is a device that stores rotational energy as it spins at high speeds. This energy, when attached to a cable and roller coaster car, helps pull the train forward.
- Catapult: A diesel engine or a dropped weight winds a cable, which pulls the roller coaster cars until they reach their full speed.
- Friction wheel: Horizontal wheels lie under the roller coaster train. Wheels on either side of a metal fin under the car spin in opposite directions, propelling the car forward.
These various systems use physics in a variety of ways in order to get roller coasters moving. Roller coaster engineers do not use these as often as others because they do not produce as much power. The power they create is not considered efficient either because they require a lot of energy to operate. Their ratio between the power and performance does not make them the best roller coaster systems out there.
The three more popular launch systems use forces and equipment that is a bit more complex. Therefore, you should narrow down your choices by comparing pneumatic, hydraulic, and electromagnetic roller coaster launch systems.
Pneumatic Vs. Hydraulic Vs. Electromagnetic Roller Coaster Launch Systems
The following roller coaster launch systems propel roller coaster trains forward as the ride begins in a variety of different ways:
- Electromagnets: Electrical impulses react with magnetic fins on the bottom of train cars. These impulses either attract the fins or repel them, causing the car to stop or move forward on the tracks. The launch system uses stator and rotor components to create a linear force that achieves propulsion. Engineers select this option when they want to control speed precisely. An electromagnetic roller coaster launch system produces greater acceleration at the start, which eventually dies down throughout the rest of the launch.
- Hydraulic: In a hydraulic system, a sled connects to the roller coaster train via a cable. As the hydraulic motor functions, the cable winds around a drum, which pulls the sled. The sled then releases the train and begins to slow down heading back to its starting spot. The motor uses incompressible hydraulic fluid in one compartment as it compresses nitrogen gas in another. The power generated throughout this process goes to the cable drum to wind the sled's cable. Engineers choose hydraulic options when they want faster and smoother acceleration, especially compared to an electromagnetic system. Some designs have more moving parts than an electromagnetic system, which sometimes impacts reliability.
- Pneumatic: A pneumatic system functions similarly to a hydraulic one. The primary difference between the two is that pneumatic launch systems replace nitrogen gas and hydraulic fluid with air. While these systems provide a constant acceleration, the loud noise they produce is a turn-off for theme parks and guests. With their loud noise also comes less-powerful propulsion.
The most common launch systems are popular for a reason. They each come with their own strengths, but as with any mechanical system, there are drawbacks. Certain varieties within these different launch mechanism categories have their advantages and disadvantages.
As previously described, an electromagnetic system uses repulsive and attractive forces to launch a roller coaster. There are two different variations in this category:
- Linear induction motors (LIM): Sets of magnets with gaps between them propel trains forward as a fin under the train passes through the gap. Currents applied to the magnets on the track create a magnetic field to affect the fin.
- Linear synchronous motors (LSM): This system uses rare earth magnets attached to the train car to either repel or attract the train in relation to electromagnets on the track. This system uses computers to reverse the magnets on the track as necessary.
Either method of electromagnetic propulsion will produce a smooth launch. However, both electromagnetic systems require a lot of energy to run. Variations between pneumatic and hydraulic mechanisms are dependent on the source of the equipment.
Any type of roller coaster launching system requires power to operate, but it is just a matter of weighing their power to performance ratio. Therefore, it is recommended to compare pneumatic, hydraulic and electromagnetic options as a roller coaster launching system is chosen.
How to Choose the Best System for a Roller Coaster
All roller coaster launching systems are responsible for keeping riders safe, but the most fitting option for an application must be chosen. When selecting a system for a roller coaster you should consider:
- Available project funds
- Allocated project space
- Height limitations
- Desired launch speed
- Safety mechanisms being incorporated
- Available power to drive the system
While passengers' safety is the utmost priority, it is not the only consideration when designing, updating, or repairing a roller coaster. It is necessary to think about the product’s longevity, as well as the potential of future repairs or replacements. Will the selected system always work for the ride? Does your budget incorporate the cost of major repairs or replacements?
If the right system is chosen, one will realize a high-quality product is the answer in preventing roller coaster accidents. Installing the right mechanism on a ride will make the launch exciting, while also safe for passengers.
For faster, smoother, and quieter acceleration, a hydraulic system may be the best option. Once the type of system is chosen, the equipment provider must carefully be considered.
Common Roller Coaster Launch System Issues
Launch systems are responsible for propelling the train forward and kickstarting the thrilling ride. Each system has unique characteristics and methods in launching roller coasters successfully. However, roller coaster launching mechanisms also have a few drawbacks that often cause issues. Some of the most common problems with roller coaster launch systems are:
- Electrical problems: Electrical problems such as electrical surges, faulty wiring, or short circuits can cause inconsistent acceleration during launch or even a failed launch. These issues can be especially detrimental to electromagnetic LIM launch systems since they rely on a nearby power source to generate motion.
- Control system failure: Some roller coasters rely on advanced technology and control systems to operate. Malfunctioning control systems can impact sensors, motors, and software. This type of failure can lead to several launch systems issues, such as inaccuracies in necessary launching power, timing issues, or improper launches.
- Electromagnetic misalignment: Structural shifts and vibrations can cause electromagnetic misalignment in the tracks. Since the magnetic fields created by the magnets on either side propel the train forward, misalignment can affect the performance and accuracy of the launch system.
- Pump failures: Hydraulic launchers utilize pumps to pressurize fluid and drive the coaster forward. If the pump fails, overheats, or is worn out, it can cause delayed or incomplete launches.
- Valve malfunctions: Valves control the flow of a fluid within hydraulic and pneumatic systems. As such, issues with valves can directly impact the overall functionality of the launch system. Faulty valves can cause irregularities in fluid pressures, affecting the timing and strength of the launch. Valve malfunctions can also cause leaks, which lead to pressure drops and inefficiencies within the system.
- Temperature sensitivity: Extreme temperatures can significantly affect the performance and longevity of roller coaster launch systems. For electromagnetic systems, temperatures impact the conductivity and responsiveness of electromagnets, and overheating can degrade their magnetic properties. Temperature fluctuations can also affect the viscosity of fluids in hydraulic systems and the density of compressed air in pneumatic systems. Both systems can also experience slow response times and reduced efficiency due to extreme temperatures.
- Maintenance requirements: Lack of regular maintenance for roller coaster launch systems could lead to many issues including faulty electrical wiring or pump failures. Proper inspection, cleaning, and timely repairs help ensure your system's longevity and smooth operation.
Launch systems need to operate correctly to give the coaster the necessary boost to reach and maintain high speeds. Issues with the system do more than hinder the train launching process — they can pose risks for the riders or even disrupt the entire roller coaster.
At York Precision Machining & Hydraulics, we have developed effective fail-safe solutions to address common issues with hydraulic launches. The Bear-Loc ® hydraulic cylinder is a state-of- the-art locking system designed to lock components in position automatically and halt movement in the event of a pressure drop. This positive locking action helps prevent potential injuries or equipment damage caused by issues within the system.
Avoiding Hydraulic Cylinder Failure
Selecting the right manufacturer for your machinery will help you avoid costly hydraulic cylinder load-holding failure. The main issues with traditional hydraulic systems are the number of moving parts they require, because more moving parts typically translates to more parts potentially needing repair. In addition, there are more possibilities of costly and risky damage or breakage. Other notable safety and performance risks include operator errors, improper maintenance, additional parts failures, and contamination of hydraulic fluid.
You cannot afford to have issues with your coaster rides’ safety and performance. We designed Bear-Loc® to solve detrimental challenges in hydraulic system load holding and locking. Bear-Loc’s® innovative, proven design gives you peace of mind and outstanding ROI because it is failsafe and reliably performs for years, even decades. Here’s how:
Costly Coaster Problems & the Bear-Loc® Solution
| Costly Coaster Problems | The Bear-Loc® Solution |
|---|---|
| Components are not safety-proof | Locks automatically when hydraulic pressure is removed, eliminating risks of operator error, power loss, & failure of other hydraulic system components (e.g. pump, valve, etc.). |
| More parts to inspect, maintain, repair | Does not depend on moving parts, valves, or other components to obtain and maintain its lock/load holding. The rod is larger than the sleeve. When hydraulic pressure is applied to the sleeve at the correct specification, the rod moves freely, with no wear. |
| Contaminated hydraulic fluid | Requires very little hydraulic fluid, which is sealed and does not leak. |
| Temperature & environmental conditions | Built to withstand high/low temperatures, weather and environmental exposures (e.g. sand, salt, water etc.) Designed to customer requirements, including special metals and coatings. |
| Movement limitations, risks | Infinite positioning along stroke enhances performance and instant bi-directional locking ensures safety (when locked, motion is not possible in any direction). |
| Too expensive to modify new design or existing equipment | Available as an actuator system or lock only unit, for new design and retrofit applications. Delivers outstanding ROI because it performs reliably for years, even decades. |
| Hesitation in locking causes performance, safety problems | Zero backlash, instant locking. |
| Limitations to size, power | Provides high system stiffness and industry leading power. Rod diameters range from 1 to 27 inches, sleeve lengths from 2.75 inches to 7 feet. Delivers up to 4 million pounds of load holding capacity. |
Choose the Right Hydraulic System for Roller Coasters
Hydraulic components will be the best choice for your roller coaster, whether you use them in launch or safety systems. You also have to make the right choice when choosing a particular hydraulic mechanism and locking components.
With a custom hydraulic cylinder and actuator from York Precision Machining & Hydraulics, your workers and park guests will be safer. Since the actuator controls the movement of a system, you want the best in the industry. Your riders will be safe at launch or other parts of their journey where you use our systems according to specifications.
Our Bear-Loc® locking feature for hydraulic components combines fail-safe reliability with an easy-to-use system. We offer a variety of custom configurations that suit any application's needs with high stiffness and zero backlash. Our high-quality parts are versatile and can even be used in confined spaces. With Bear-Loc® systems in place, passengers will experience an exciting and safe ride.
When you choose a hydraulic system for roller coasters, riders' safety is the top priority. We understand the risk of accidents on any machinery that requires a hydraulic system, and we want to provide the safest option for engineers. When operated according to specifications, our hydraulic actuators and cylinders keep riders and workers safe. If pressure is lost or removed, the Bear-Loc® locks in place, preventing harm to anyone near the system. We work hard to create a system with unique fail-safe properties to ensure secure operation.
Contact us online or give us a call at (717) 764-8855 if you're ready to see what our safe hydraulic locking systems can do for you.
Awards & Certifications
ITAR Registered #M39417
Outstanding Performance
Excellence Presented By Commander
SIBC Member
ACIBC Member
NFPA Member
