Coasters 101 An Engineer’s Guide to Roller Coaster Design Nick Weisenberger Third Edition Coasters 101: An Engineer’s Guide to Roller Coaster Design Contents Copyright Information ....................................................................... 4 Disclaimer .......................................................................................... 5 Chapter 1: Introduction ...................................................................... 9 The Three Dimensional Puzzle ...................................................... 9 Brief History of the Roller Coaster .............................................. 10 Coaster Classification .................................................................. 13 Wood versus Steel........................................................................ 16 Design Software and Computer Technology ............................... 18 Chapter 2: Planning.......................................................................... 23 Design Constraints and Considerations ....................................... 25 Selecting a Manufacturer ............................................................. 28 Layout and Profile ........................................................................ 29 Chapter 3: Design Principles ........................................................... 31 G-Forces ....................................................................................... 31 Kinetic and Potential Energy ....................................................... 33 Friction and Drag ......................................................................... 34 Chapter 4: Coaster Elements ............................................................ 37 Lifting Mechanisms ..................................................................... 37 Lift Energy Example ................................................................ 39 Launch Systems ........................................................................... 40 A People-Powered Coaster .......................................................... 44 Vertical Loops .............................................................................. 45 Banking the Track through a Curve ............................................. 47 Curve Design Example ............................................................ 50 Chapter 5: Vehicle Design ............................................................... 53 Seating Configuration .................................................................. 53 Wheel Design and Material Selection .......................................... 54 Resistance .................................................................................... 59 Restraint Design ........................................................................... 61 Vehicle Design Example .......................................................... 62 How a 4D Coaster Works ............................................................ 64 Chapter 6: Infrastructure .................................................................. 67 Supports and Foundations ............................................................ 67 Brakes, Blocks, Sensors, and Switches ........................................ 69 2 Nick Weisenberger Racing/Dueling Control Systems ................................................ 72 Chapter 7: From Paper to the Park................................................... 75 Ride Analysis ............................................................................... 75 Construction ................................................................................. 76 Test and Adjust ............................................................................ 77 Operation ..................................................................................... 79 Chapter 8: Safety ............................................................................. 81 Amusement Industry Safety Standards ........................................ 81 Section A12: Wooden Coaster Restraints ................................ 84 Lock Out Tag Out Procedures ..................................................... 84 Inspections and Maintenance ....................................................... 86 Chapter 9: Design Example ............................................................. 89 Chapter 10: Career Advice .............................................................. 93 Chapter 11: Enjoy the Ride .............................................................. 99 About the Author ........................................................................... 103 Appendix I: Acronyms................................................................... 105 Appendix II: Glossary .................................................................... 106 Appendix III: Notable Dates in Roller Coaster History ................ 109 Appendix IV: Resources ................................................................ 112 Professional Organizations .................................................... 112 Student Organizations ............................................................ 112 Websites ................................................................................. 113 Books ..................................................................................... 113 3 Coasters 101: An Engineer’s Guide to Roller Coaster Design Copyright Information Third Edition – First printed November 2013 Copyright ©2013 by Nick Weisenberger All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage and retrieval system, without permission in writing by the author. The only exception is by a reviewer, who may quote short excerpts in a review. Cover layout and design by John Stevenson 3D renderings by Patrick McGarvey Photographs by Nick Weisenberger No affiliation with, or endorsed by anyone associated, or in any way connected with any amusement park, company, or product listed herein. ISBN-10: 1468013556 ISBN-13: 978-1468013559 4 Nick Weisenberger Disclaimer Although the author has attempted to exhaustively research all sources to ensure the accuracy and completeness of information on the subject matter, the author assumes no responsibility for errors, inaccuracies, omissions, or any other inconsistencies herein. We recognize that some words, model names and designations, for example, mentioned herein are the property of the trademark owner. We use them for identification purposes only. This is not an official publication. The purpose of this text is to complement and supplement other texts and resources. You are urged to read all the available literature, learn as much as you can about the field of engineering, and adapt the information to your particular needs. There may be mistakes within this manual. The information contained herein is intended to be of general interest to you and is provided “as is”, and it does not address the circumstances of any particular individual or entity. Nothing herein constitutes professional advice, nor does it constitute a comprehensive or complete statement of the issues discussed thereto. Therefore, the text should only be used as a general and introductory guide and not as the sole source for roller coaster engineering. Side effects of reading this book may include dizziness, nausea, or the sudden urge to visit a theme park. 5 Coasters 101: An Engineer’s Guide to Roller Coaster Design 6 Nick Weisenberger Coasters 101 is dedicated to all aspiring roller coaster designers. Never give up on your dreams! 7 Coasters 101: An Engineer’s Guide to Roller Coaster Design 8 Nick Weisenberger Chapter 1: Introduction The Three Dimensional Puzzle Have you ever wondered what it takes to design a roller coaster? It’s not as easy as computer games make it out to be! A roller coaster, while simple in terms of the sheer thrill it gives to those who ride it, is a complex three-dimensional puzzle consisting of thousands of individual components. There is no apprenticeship or degree specifically targeted at engineering a roller coaster. Whether it’s wood or steel construction, the job is an interdisciplinary mix of structural, mechanical, civil, and electrical engineering. No two roller coasters are designed exactly the same way. Each project has its own unique set of circumstances and challenges. A perfect blend of engineering and art, roller coaster designers spend countless hours creating and tweaking ride paths to push the envelope of exhilaration all while maintaining the highest standards for safety. The academic definition of the term 101 means “the introductory material in a course of study.” Coincidentally, the term 101 is as common at theme parks as it is on a campus. If an attraction shuts down for whatever reason, a string of messages will fly back and forth between the operations and maintenance staff. This used to be accomplished via hand-held radios or walkie-talkies. In order to avoid a guest over hearing the details of a broken down ride it was common practice to use the code number 101 rather than announce “The ride is down” to anyone within earshot. Nowadays, with texting and smart phones replacing radios, it’s no longer as critical but is still a convenient coincidence. Coasters 101: An Engineer’s Guide to Roller Coaster Design examines the numerous diverse aspects of roller coaster creation including some of the mathematical formulas and engineering concepts that go into designing a multimillion