Segmented Planar Steel Roller Coaster Track Fabrication
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Solution Overview
Problem
Traditional methods of fabricating roller coaster tracks and other curved structures using heated and bent steel result in material fatigue, structural integrity issues, and frequent replacement due to inherent manufacturing stresses and dynamic loads, leading to suboptimal designs and increased costs.
Innovation Solution
The method involves cutting and welding together planar steel pieces to form a three-dimensional, elongated, curved structure like an I-box style track, using specialized computer software for design and conventional cutting tools, minimizing manufacturing stresses and allowing for precise fabrication of complex curves without heating or bending, thus maintaining material strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If steel rod or steel pipe is heated and bent to form curved tracks, then the desired shape can be acquired, but significant material fatigue is caused and structural integrity deteriorates
Solution Approach 1:
The track is divided into multiple straight segments that are connected at angles to form curved paths. Each segment maintains its original straight shape without bending, eliminating manufacturing stresses while achieving the desired curved track configuration through geometric arrangement of segments
Solution Approach 2:
The track design transitions from two-dimensional curved surfaces to three-dimensional angular constructions using straight segments. By utilizing spatial arrangement and angular connections in 3D space, the track achieves complex curved trajectories without requiring bending of individual components
2Manufacturing precision
If steel pipe is heated and bent into complex designs, then the desired track configuration can be achieved, but the track does not bend as desired and repeated fabrication attempts are needed
Solution Approach 1:
The track is segmented into straight sections that can be precisely manufactured and then assembled at specific angles. This segmentation allows each component to be fabricated with high precision using standard processes, and the final curved configuration is achieved through precise angular assembly rather than complex bending operations
Solution Approach 2:
Straight track segments are pre-fabricated to exact specifications before assembly. The precise angles and dimensions are established during manufacturing of individual segments, ensuring that when assembled, the final track configuration matches the design requirements without requiring repeated adjustments
3Ease of manufacture
If traditional bent steel pipe track is used, then the track can be manufactured, but manufacturing stresses and dynamic loads cause frequent replacement over time
Solution Approach 1:
The track system is divided into modular straight segments that can be manufactured using simple, reliable processes without inducing stresses. These stress-free segments are assembled into the final curved configuration, ensuring long-term durability while maintaining ease of manufacture through standardized component production
Solution Approach 2:
The fundamental manufacturing parameter changes from bending and heating operations to cutting and angular assembly operations. This parameter change eliminates the introduction of manufacturing stresses while maintaining manufacturability through precise cutting and assembly processes
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
A method of fabricating an amusement park ride track utilizing stock, planar materials, namely comprising of creating elongated, curved structures from planar materials. A roller coaster track capable of being fabricated from multiple planar pieces without heating or bending. Other embodiments are described which utilize elongated, curved structures such as ski lifts, people movers, staircases and architectural structures. A jig is disclosed for providing for ease of manufacture of the elongated, curved structures.