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.

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.

Compact solution

The combination of the ALF306 force sensor, which is only 10 mm thick, and the portable TD-01 handheld measuring device enables precise brake force measurements even in confined conditions – ideal for maintenance work directly on the system.
Robust, mobile construction

The entire measuring device is protected against external influences and optimised for mobile use – including a carrying handle for easy handling during maintenance work.
Reliable measurement results

Through the use of high-precision sensor technology and mobile data collection, the measured values can be reliably documented and compared with safety-related limit values.
Increased safety & predictable maintenance

The solution enables targeted monitoring of braking forces and helps to detect wear in good time. This not only increases operational safety, but also makes maintenance planning more efficient and transparent.

Product details: ALF306 Pancake Force Sensor

The very flat, disc-shaped force transducers of the ALF306 series are transducers for measuring compressive forces in the measuring ranges from 50 N to 10 kN in very confined spaces. A special version with a measuring range up to 20 kN was manufactured for the roller coaster.

The ALF306 is just 10 mm high and has a diameter of 40 mm. This means it can also absorb some of the shear forces generated.

Key features

Measuring ranges 0 … 50 N to 0 … 10 kN or according to customer requirements
For compressive loads
Linearity deviation 0.3 % of full scale (Model 1), 0.5 % of full scale (Model 2)
Output signal 1.2 mV/V or standardised 1.0 mV/V ±0.5% (Model 1), 2.2 mV/V or standardised 2.0 mV/V ±0.5% (Model 2)
Supply voltage 10 VDC

Data acquisition and evaluation

The TD-01 is a mobile, digital display device for strain gauges (SG) with a colour display. It not only allows measured values to be displayed in numbers and curves, but also enables dynamic signals to be stored via a high-speed A/D converter.

Key features

Portable device with colour TFT display
TEDS function for automatic sensor recognition
USB interface (operation and data transfer)
Dual input, suitable for 0.3 mV/V to 5 mV/V
Visualisation: waveform or bar display
Power supply via USB or AA batteries (up to 24 hours)

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.