New Composite-Body Mountain Coaster Cars Bring Fresh Perspective to Entertainment Sector

Abstract

Glass fiber reinforced composite materials have become the material of choice in many different sectors due to their low production costs, high specific mechanical properties, ease of design and shaping, and numerous other advantages. Their use in aviation, military and space fields is increasing day by day. Accordingly, such materials have emerged as attracting considerable attention and driving successful developments, particularly in the automotive industry. Glass fiber reinforced composite materials constitute approximately 90% of our product range. Within the scope of our commitment to innovative and sustainable work as a company, a new product study has been completed to add a new R&D initiative to our product range and to offer a fresh perspective to the entertainment industry. The Mountain Coaster (Trail Coaster) recreational vehicles, whose outer shell is manufactured using FRP composite material and whose design and engineering work has been created within our own R&D structure, have been designed. Our vehicle, which we produce as 100% domestic production, has succeeded in becoming a preferred product by bringing a new perspective to the entertainment industry.

Composite Body Mountain Coaster Vehicle

Polin Water Parks, established in Istanbul in 1976, is a world leader in the design, production and assembly of water slides and water parks. Polin, which has completed more than 3,000 water park projects in 105 countries, has achieved numerous firsts through its innovative approach, superior quality standards and technological leadership. Today, the largest and award-winning water parks in many countries, even across continents, bear the Polin signature. The King Cobra slide launched by Polin, which has the widest product range in the world, was selected as the best water slide in Europe in 2014 and 2015. Polin has been using RTM (Resin Transfer Molding) closed mold technology since 2006, which offers significant advantages such as the production of aerospace systems. Polin slides with bright surfaces on both sides, smooth finishes, greater strength and lighter weight, with excellent visual quality and product performance, have become innovations in RTM technology. This technology represents the most advanced approach in slide production. Polin is the first and only European water slide manufacturer to produce using this production technique. All design, production, assembly and service processes of Polin water slides have been subject to ISO International Quality Management systems since 2003; they are carried out in accordance with European (EN) and American (ASTM) standards. Polin is the first European water slide manufacturer to hold this quality certification.

Polin, which continues to add award-winning water slides and water park projects day by day, attaches great importance to new product development.

Our R&D studies are advancing rapidly in order to provide innovative perspectives to the entertainment industry, to design new products and to make designed products productive and implementable. Figure 1. Our award-winning water slide Figure 2. Our sample projects With the introduction of composite materials to the Turkish automotive industry for the first time in the vehicle body of Anadol brand in the 1960s, and their rapid expansion in the following years, the use of composites in interior and exterior components of vehicles of many different types became rapidly widespread. Many applications were carried out using the simple hand lay-up method. In more recent processes, production methods and techniques have been developed, mass production has begun, and composite materials have started to be used in much wider areas. In this context, with our design and engineering capabilities, our Mountain Coaster (Trail Coaster) product, which we have been developing within our own R&D structure and have proven to be innovative with 100% domestic production, is an important example of multidisciplinary systems used together in the automotive, entertainment and composite sectors.

Glass fiber reinforced composite material was selected for Mountain Coaster vehicle design due to its many features such as low density, high strength, rigidity and high production speed.

Mountain coaster is a system that generates adrenaline through two-person coasters moving over rails installed on a slope. In a natural environment, the design of the system maximizes both excitement and safety factors, allowing downhill speeds up to 40 km/h through gravity alone.     Figure 3. Mountain coaster model             Rails may be designed in lengths varying between 700 m and 4,000 m according to the span and inclination of the terrain. Average land slope must be minimum 7% (4°). Rails must be installed on supports in accordance with the topography of the land. Land may be levelled if necessary.

Curve radii must comply with standards and desired speed, and may vary between 4 m and 9 m. Slope angle must be calculated accordingly to maintain optimal driving performance.

Peaks and valleys in the rail design allow for different driving experiences. Trees and natural structures are preserved in the design. Tunnels and bridges may be incorporated if necessary.

Figure 4. Mountain train track model

Ergonomically designed sleds can accommodate 1 or 2 persons. The sleds are designed to allow children between ages 3 and 8 to ride together with an adult and children older than 8 to ride independently.

Figure 5. Mountain train user view

Thanks to the braking system, users can safely operate the sleds at desired speeds. When the braking system is not engaged, the sleds automatically shift to automatic braking mode and can only be accelerated intentionally. The sleds are equipped with safety belts. Safety belts cannot be released while the sleds are in motion. Automatic clutches prevent exceeding the standard maximum speed, defined as 40 km/h. The sleds, finished with energy-absorbing elegant bumpers, can be ordered in any color. Mountain coaster consists of rails, sleds, climbing conveyor, signalization system (automation) and a station building.

Climbing Conveyor and/or Sled Lift

This system carries suspended sleds to the upper level with or without riders. It may be designed for slopes up to 40% (22°). Climbing speed may be adjusted according to desired capacity.

Automation System with Emergency Brake

This system controls the vehicles moving on the rails, provides vehicle data to the operator and ensures that vehicles approach each other slowly in case users fail to apply the brakes.

Station Building

The station building, designed according to project size, includes the platform for sled boarding and disembarking and the operator area. In addition, it also includes storage space, sled lift and a maintenance area.

Rail System

All wear and thermal deformations are considered in the design of the rails, which are made of 316L stainless steel. In the entertainment equipment industry, where user safety is the paramount concern, rail engineering is detailed to the finest specifications. Necessary precautions are taken to ensure both user safety and environmental safety. The automatic braking system that maintains sled spacing on the rails is optional. The automatic braking system prevents sleds from approaching closer than 40 m to each other.  

Figure 6. Mountain train user view

Thanks We would like to thank our R&D Director Ali Cansun and Polin Water Parks for supporting this work.