Rides Intelligent safety systems for roller coasters

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Hawe Micro Fluid manufactures an essential component for restraint systems in roller coasters with the hydraulic locking system LE-X. The company relies on thread technology from Igus.

Mr. Stratmann, you are a product manager at Hawe. When roller coasters whizz over the tracks at 100 kilometers (approx. 60 mph) per hour or more, enormous forces act on the body and the wagons. What role does your solution play in this?

Eike Stratmann: Our retention systems ensure that the safety bars of the ride always remain closed. The hydraulic cylinders we have developed are so compact and sturdy that they are actually suitable for any type of roller coaster – classic ride, VR ride or even water roller coaster. With the LE-X retention solution, we can cater to any type of seat, including shoulder, lap, and stomach bars. We have been present in the market with our systems for over 20 years and have been able to improve the previous systems HLU LE 25 and 32 in every aspect with the new version.

Which would be?

Stratmann: We were able to significantly increase the usage life, from previously seven years to ten years or one million cycles for HLU LE-X (M) – whatever comes first – and two million cycles for HLU LE-X (E). The cylinder has become even smaller, and now a stroke of 80 to 250 millimeters is possible – instead of previously up to 150 millimeters. In addition, the expanded sensor technology for HLU LE-X (E) now allows us to offer detailed data analysis and predictive maintenance at the cutting edge of technology. An important partner in the development from the beginning was Igus.

Mr. Liebsch, as the product manager for the Dryspin thread technology at Igus, how do you think the project went?

Julian Liebsch: We were involved very early in the development process of the spindle assembly, which is central to the HLU LE-X (E), by Hawe. A great advantage was that Hawe was very transparent and always provided us with many pieces of information. We quickly realized that our Dryspin thread technology is the right solution for the locking system. Here, we use thread nuts made from our lubricant-free, maintenance-free, and wear-resistant high-performance plastics. The properties and geometries of our thread technology, which are matched to the plastic nut and spindle, guarantee efficiencies of up to 82 percent and a life expectancy that is up to 30 percent longer than conventional threaded drives.

Mr. Stratmann, why did you choose Igus?

Stratmann: Quite simply, Igus has met all our requirements with regard to validations with its thread technology. As already mentioned, one of the core requirements of our customers in development was improved longevity. We have applied 12 million load cycles to the spindle assembly of the HLU LE-X (E), and it has held up. That convinced us. In addition, Igus has continuously supplied us with calculations and relevant values.

How do you manage to make statements about so many millions of cycles?

Liebsch: We at Igus have a lot of experience in calculating the life expectancy of our products. This is mainly due to our in-house test laboratory at our headquarters in Cologne, which covers more than 4,000 square meters. Every one of our products is tested there in different application cases and over a long period of time. This allows us to provide the customer with reliable information even before the purchase, about how long the product will last and how it will behave in the application. For even more functional safety, we now even offer our customers a warranty of up to four years on all Igus products with an online life expectancy calculation, including our Dryspin thread technology.

In the end, you chose the Dryspin thread technology and the Iglidur J material. Why?

Liebsch: Originally, the requirement was that the material should withstand one million cycles. For this reason, we had initially chosen the Iglidur E7 material for the thread nut. As a soft, vibration and vibration-damping material, it is ideal for these conditions. Even there, the first tests showed that we can run over ten million cycles without wear. Later in the project, Hawe adjusted the thread nut geometry again and added an external thread. In order to continue to ensure the necessary strength, we finally decided to use our versatile long runner Iglidur J for the thread nut material. The required mileage was no problem at all here.

Stratmann: These experiences were very valuable to us. Avoiding abrasion is incredibly important in our closed hydraulic circuit in the cylinders. Abrasion in the system carries the risk that the safety valve cannot close properly and, in the worst case, the bar opens during the ride. With Iglidur J, we can now always be sure that the bar remains closed.

Intelligent data processing is making its way not only into industry, but also into roller coasters. What's in it for the amusement parks?

Stratmann: The HLU LE-X (E) locking system is equipped with a very detailed data collection. Status data is stored in the electronics, which is later analyzed in the cloud using artificial intelligence. The algorithms then calculate a predicted replacement date, long before an actual failure would threaten. One value, for example, is the tightness of the cylinder: a limit is already written into the electronics during production. Should a limit actually be exceeded, it will be displayed to the user after the data upload on the computer. The status data is visualized in a dashboard. This takes the load off the local staff, as it eliminates a large portion of time-consuming control rounds. It's the same in the amusement park.

Currently, there is a weekly check-up in the parks. This means that the mechanic has to check the locking system of each seat once a week with a special preload device that checks the cylinder tightness. The cylinder works if it does not give way. With the sensors in the LE-X, we can check this automatically, so no preload device is needed anymore. The manual inspection for two cylinders per seat takes about ten minutes. With the large number of seats and many different rides in amusement parks, mechanics are thus saving a lot of time.

Where can your systems be found everywhere?

Stratmann: We are active worldwide and mainly serve the seat classes four and five according to DIN EN 13814 with the LE-X kit, these are the seats with the highest safety requirements. Often they are so-called thrill rides with loops or similar elements, where movement takes place on multiple axes. With the LE-X kit, we offer suitable products for this segment and want to continue to grow in the future.

What will the cooperation between Hawe and Igus look like in the future?

Stratmann: The cooperation with igus was on an equal footing and always very collegial. We had no problems with the validation and the first practical experiences with the new product are consistently positive. Igus is clearly the partner we want to continue working with in the future.

Liebsch: We too, through our cooperation with Hawe, have gained completely new experiences in a very exciting industry. In addition, we were able to prove that our patented Dryspin steep thread technology is just right for applications that need to meet high demands on material, safety, and service life. For this reason, we are looking forward to further cooperation!