Rollercoaster Track Assembly Using Computer-Cut Wood Segments

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Solution Overview

Problem

Conventional wooden roller coaster track construction is labor-intensive, costly, and prone to imperfections due to manual bending and cutting, requiring skilled labor and time-consuming adjustments.

Innovation Solution

A track assembly method using prefabricated, stacked layers of wood segments cut with automated precision, aligned with computer-generated models, allowing for efficient and accurate assembly without the need for highly skilled labor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual bending and cutting of dimensional lumber is used, then the track can be formed to match the overall profile, but the process becomes costly and time-consuming with repeated adjustments

Engineering Contradiction:

Improvetrack profile accuracyVSAvoidconstruction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-cutting and pre-shaping the dimensional lumber segments according to a computer-generated model before assembly. The segments are prepared with precise dimensions and curvature radii in advance, eliminating the need for repeated on-site adjustments and manual bending operations, thus resolving the contradiction between precision and productivity

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If manual bending and cutting is used, then the track profile can be matched, but highly skilled labor is required which is scarce and expensive

Engineering Contradiction:

Improvetrack profile accuracyVSAvoidlabor skill requirement

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical bending and cutting operations with a computer-generated model-based automated cutting system. The computer model dictates the precise dimensions, curvature radii, and segment configurations, substituting skilled manual labor with automated computational control, thereby reducing skill requirements while maintaining high precision

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a computer-generated model as a digital copy of the desired track profile. This digital model is then used to automatically generate cutting instructions for dimensional lumber segments, replacing the need for skilled artisans to manually interpret and execute complex curvature requirements, thus reducing labor skill requirements

Inventive Principle:

Principle #26Copying

3Reliability

If manual cutting in the strong direction is used, then the track can be formed, but repeated adjustment is required which is costly and time consuming

Engineering Contradiction:

Improvetrack construction qualityVSAvoidadjustment time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If conventional track assembly is used, then the track can be constructed, but the process is labor-intensive and costly

Engineering Contradiction:

Improveconstruction feasibilityVSAvoidconstruction efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent divides the track into multiple discrete dimensional lumber segments with specific curvature radii and dimensions. These segmented components are pre-fabricated according to a computer model and then assembled together, replacing the labor-intensive conventional process of manually bending and cutting continuous lumber, thus improving construction efficiency while maintaining feasibility

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20250325913A1Track for rolling vehicle and methods of fabricating and assembling the track

Publication Date: 2025.10.23 THE GRAVITY GRP LLC

AI summary

A rail section of a rollercoaster track is provided. The track includes a plurality of layers that are each constructed from a plurality of planar segments that are bent to form a three-dimensional curve.