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The Engineering behind Roller Coasters

Ffion Collins
Oct 9, 20244 min read

Roller coasters are usually the most popular attractions at any theme park. Each design is unique in its own way, yet the basic mechanisms can be found in thousands of parks worldwide. The industry is booming, with global amusement park revenues estimated to reach $69.5 billion by 2025. But how many people stop to think about how these rides are actually made?


Theme parks normally have massive teams working behind the scenes to create magical experiences for visitors. These engineering teams have a range of responsibilities, which range from  completing design projects for the park to planning, building, and maintaining accessory structures such as maintenance sheds and queueing areas for riders. 


How are roller coasters designed?


Modern roller coasters continue the tradition of engineering and inventiveness in roller coaster design. The world’s most basic roller coasters are built using the same basic design principles as remarkable rides like Kingda Ka, which soars to heights of over 450 feet. Coasters come in almost infinite varieties, ranging from thrill rides like Great America’s RailBlazer to themed rides like Shanghai Disneyland’s Tron Lightcycle Power Run. These factors include intended rider, preferred material, cart type and track layout. 


Certain decisions will undoubtedly direct coaster engineers' work regardless of the type of ride they intend to construct. To provide the coaster its initial kinetic energy, for example, which is required to propel the cart the remaining distance, a lift mechanism needs to be identified. Chain lifts and catapult-launch systems are the two primary categories of lift devices. The train will also require well thought out braking systems once it is moving. While some braking systems are used to fully stop the train at the end of the ride or in an emergency, other braking systems are intended to slow the train down to maintain it within safe operating limitations. In addition to adding to a ride's excitement, hills, loops, and helixes are other design elements that engineers must take into account. These elements are also crucial in controlling g-forces, as hills add energy to the train as it climbs, pushing it throughout the ride, and loops slow down the train to stop riders from blacking out.


The Components of a Roller Coaster


  • Chain Lifts: If you enjoy riding rollercoasters, you are probably accustomed to the sensation of being lifted up that initial slope. A chain that runs underneath the track raises each rollercoaster to the top of the first drop before it begins its spin around the track. Like a conveyor belt, the train is propelled along by a small motor that powers the chain lift. The train descends the hill into a controlled free fall after the chain releases its grip.

  • Brakes: Roller coasters are fitted with special brakes so that they can stop around the track. These brakes are actually integrated into the tracks in the form of clamps, rather than on the train itself. Rollercoaster brakes are operated using a collection of electrical positional sensors and pneumatically (air) operated components which can close the clamps and bring the train to a stop if necessary.


What are the Differences Between Wooden and Steel Roller Coasters?


Massive wooden trestle-style structures hold the track above ground on wooden coasters. To stop degradation, they are constructed from painted or otherwise treated Douglas fir or southern yellow pine. Bolts and nails are used to link the timber components, which are supported by concrete foundations. Steel plates are used to reinforce crucial joints.


A huge amount of components go into making wooden coasters. For instance, there are 2,000 concrete foundations, 1.6 million feet of wood, 60,720 bolts, and 30,600 pounds of nails in American Eagle at Six Flags in Gumee, Illinois. Nine thousand gallons of paint are applied to it.


Thick, tubular supports or narrow, trestle-style structures are used in the construction of steel coasters. Typically, the track is constructed in segments using two welded round steel tubes that are supported by thick round tubular track supports or rectangular box girders. The steel stanchions hold the tubes in place. 2,215 tonnes of steel, 60,000 bolts, 1,270 piles pushed into the sandy soil for the foundation, and 42,000 square yards of painted surfaces make up the Pepsi Max Big One coaster at Blackpool Pleasure Beach in England.


The cars on both varieties of coasters typically have steel axles and substructures, and they both use steel track and lift chains. Car wheels are cast from urethane or other durable, silent materials, whereas car bodywork are made of fibreglass or aluminium.


In summary, the engineering of a roller coaster is an amazing fusion of accuracy, creativity, and science. From creating exhilarating curves to guaranteeing the greatest safety standards, engineers have to strike a balance between technical precision and heart-pounding excitement. Each bend, drop, and loop serves as a monument to the inventiveness and might of physics. Roller coasters will change as technology develops, providing riders with ever-more thrilling sensations while maintaining safety. In the end, creating unforgettable moments of ecstasy and excitement is the essence of roller coaster engineering, turning each ride into a one-of-a-kind experience.



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