Produkt-Neuheit

A manufacturer of roller coasters and amusement park attractions required a mobile measurement solution to check the braking forces on a roller coaster. The aim was to reliably check the braking performance on particularly flat sections of track during maintenance work. Althen supplied a compact solution consisting of an ALF306 flat profile force sensor and a TD-01 portable handheld measuring device.

Maximum safety at maximum speed
Safety is at the heart of every roller coaster development. High speeds, large masses and changing environmental conditions place extreme demands on braking and safety systems. To ensure reliable, controlled and compliant operation at all times, manufacturers need innovative solutions that enable precise measurements, reproducible tests and maximum operational safety.

About the braking system
The roller coaster in this project has a hydraulic brake. It is activated by a hydraulic cylinder that triggers the brake mechanism. The brake blocks are sheared together forcefully so that the forces acting on the fin of the train are reliably absorbed and the ride is safely slowed down or stopped.

The braking system of a roller coaster is usually located at several clearly defined points along the track. Many roller coasters have several sections (blocks) so that multiple trains can be operated safely. At each transition, a train can be brought to a complete stop if necessary. In this case, the force should be determined on a flat section of the track.

Requirements and objectives:

- Verification of minimum braking force on defined sections of track
- Quick installation even in confined spaces
- Reproducible measurement results
- Robust and mobile design for use in the field

Measuring solution form Althen
Over time, the brake blocks on a roller coaster lose their profile and the braking force decreases. In order to monitor whether the braking force is still functional and how high it is, a mobile measuring solution for maintenance should be built.

To determine the braking forces, a compact, robust box was developed with a very flat ALF306 force sensor integrated into it. On the top is a contact plate through which the brake element transfers the force directly to the sensor. The bottom forms a stable base plate with which the device can be quickly and securely attached to the brake structure or a suitable mounting point. A protective housing encloses the entire construction and protects the sensor from external influences. There is also a carrying handle, which also makes it easier to ‘engage’ the brake.

Results & benefits
The mobile solution enables reliable checking of braking force directly on site. The measurement data is compared with predefined limit values to ensure that safety-relevant minimum forces are not exceeded. In the event of deviations, maintenance can intervene in a targeted manner, e.g. by replacing worn brake blocks. The result: greater safety, predictable maintenance intervals and documentable testing processes.

Thanks to the compact design of the ALF306 and mobile data acquisition with the TD-01, a tailor-made solution was provided that is ideal for tight installation situations. The company thus benefits from a practical system for quality assurance and maintenance of its safety-critical rides.

The data itself is recorded using a mobile hand-held measuring device (TD-01). For this purpose, the device is held in the brake during the necessary maintenance work.

More information: https://www.althensensors.com/projects/measurement-of-braking-forces-on-the-roller-coaster/