Flattened Tongue Diagonal Struts for Rollercoaster Welding
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Solution Overview
Problem
The production of welded connections between diagonal and transverse struts in roller coaster track elements is complex due to the need for precise calculation and high fatigue strength, especially in curved or helically wound tracks, leading to inefficiencies and safety concerns under dynamic loads.
Innovation Solution
Flattening the ends of diagonal struts into double-walled tongues with rectangular abutting surfaces simplifies the connection process, allowing for easier weld preparation and safer welding to transverse struts, even in complex track configurations, with the option to twist the tongues for standard-compliant clearance angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If diagonal struts with round tube cross-section are used for welded connections to transverse struts, then structural strength is achieved, but manufacturing complexity and production effort increase significantly due to precise calculation and welding requirements
Solution Approach 1:
The invention changes the geometric parameter of the diagonal strut end from a circular cross-section to a flattened tongue shape with rectangular cross-section. This parameter change transforms the complex curved abutting surface into a flat surface that is parallel to the transverse strut side face, dramatically simplifying the welding preparation and execution while maintaining the required fatigue strength under dynamic loads.
Solution Approach 2:
The diagonal strut end is asymmetrically shaped with a flattened tongue configuration rather than a symmetric circular tube end. This asymmetric design creates a flat abutting surface that aligns with the transverse strut, eliminating the need for complex angular calculations and multi-axis positioning during welding, thus reducing manufacturing complexity while preserving structural integrity.
2Adaptability or versatility
If curved and helically wound track configurations are used to achieve exciting roller coaster routes, then ride experience is improved, but calculation and production of abutting surfaces for diagonal struts becomes extremely complex
Solution Approach 1:
By changing the end geometry parameter of the diagonal strut to a flattened tongue shape, the invention decouples the welding preparation complexity from the track curvature. The flat abutting surface can be consistently produced regardless of whether the track is straight, curved, or helically wound, eliminating the need for complex per-case calculations and enabling standardized production across all track configurations.
Solution Approach 2:
The diagonal strut is segmented into a tubular body and a flattened tongue end section. This segmentation allows the tongue end to be independently formed with a standard flat geometry that simplifies welding, while the tubular body maintains the structural requirements for various track configurations including curves and helical winds.
3Quantity of substance
If standard circular tube diagonal struts are used, then material utilization is efficient, but weld seam preparation and execution require extreme precision and multiple operations
Solution Approach 1:
The end section of the diagonal strut is transformed from a circular tube end to a flattened tongue with rectangular cross-section. This parameter change enables single-operation cutting and welding preparation, eliminating the need for multiple precision operations required for circular tube ends, thus dramatically improving welding productivity while using the same material efficiently.
Data Source
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AI summary
The coaster has diagonal struts (20) provided between transverse struts (13) and consisting of hollow profiles i.e. tubes. The diagonal struts are welded with the transverse struts, and two sides of the diagonal struts are flattened for forming plane, double-walled guides (21). The two sides of the diagonal struts cut to a length in such a manner that longitudinal edges of outer front surfaces of the diagonal struts run parallel to side surfaces of the transverse struts. The transverse struts have rectangular cross-section, and the diagonal struts have circular cross-section.