A New Perspective in the Entertainment Sector: Mountain Sled Cars with Composite Bodies

Summary

Glass fiber reinforced composite materials have become the preferred material in many different sectors due to low production costs, high specific mechanical properties, ease of design and formability, and numerous other reasons. Their use in aviation, military and space applications is increasing day by day. Accordingly, the material has attracted considerable interest in the automotive sector and has emerged as a material that has guided successful studies. Glass fiber reinforced composite materials constitute approximately 90% of our product range. As part of our commitment to innovative and sustainable work as a company, we have completed a new product development project to add a new research and development study to our product diversity and bring a fresh perspective to the entertainment sector. Trail Coaster entertainment vehicles have been designed with an external shell made using CTP composite material, with all design and engineering work completed within our own R&D department. Our vehicle, produced as 100% domestic manufacturing, has succeeded in bringing a different perspective to the entertainment sector and becoming one of the preferred products.

CTP Composite Body Trail Coaster Vehicle

Polin Waterparks, established in Istanbul in 1976, is a world leader in water slide and water park design, manufacturing and installation. Polin, which has completed more than 3,000 water park projects in 105 countries, has achieved many firsts with its innovative approach, superior quality understanding and technological leadership. Today, the largest and award-winning water parks in many countries, even continents, bear the Polin signature. Polin's King Cobra slide, launched in 2010 and boasting the world's widest product diversity, was selected as Europe's best water slide in 2014 and 2015. Since 2006, Polin has used RTM (Resin Transfer Molding) closed mold technology, a manufacturing method used in space systems, to produce water slides with shiny surfaces on both sides and smooth finishes, greater durability and lighter weight, improved aesthetics and superior product quality. This technology represents the most advanced point in slide manufacturing. Polin is the first and only European water slide manufacturer to use this production technique. All design, manufacturing, assembly and service processes of Polin water slides have been conducted since 2003 under the ISO International Quality Management system in compliance with European (EN) and American (ASTM) standards. Polin is the first European water slide manufacturer to hold this quality certificate. Polin, adding new ones to its award-winning water slides and water park projects each day, places great emphasis on new product development studies. Our innovative and sustainable work continues through rapid R&D efforts to bring new perspectives to the entertainment sector, design new products and make designed products producible and projectizable. Figure 1. Our award-winning King Cobra slide Figure 2. Examples from our projects The use of composite materials first started in the Turkish automotive industry in the 1960s in the Anadol brand automobile carport, and with its rapid spread in subsequent years, its use in many different concept vehicles and in-vehicle and external equipment expanded rapidly. Many applications were carried out using the easy-to-manufacture hand lay-up method. In subsequent periods, production methods and techniques were developed, mass production began, and composite materials started to be used in much broader fields. In this context, our Trail Coaster product, designed and engineered entirely within our own R&D department, developed by us, and proven in its originality through 100% domestic production, will be an important value product in the automotive, entertainment and composite sectors, where multidisciplinary systems are used together. Due to the low density of composite materials, high strength, rigidity and high production speed, among many other characteristics that could be mentioned, glass fiber reinforced composite material was selected for the Trail Coaster carriage design. With our Trail Coaster product, our aim is to provide users with an exciting adventure in close contact with nature through two-person sleds moving on tracks built on sloped terrain. In the design of the system, which can accelerate down the slope to speeds of up to 40 km/hour using only gravity, excitement and safety have been prioritized. Each facility is designed with its own unique track layout. In this way, users experience an extraordinary driving experience on different turns.

Figure 3. Trail Coaster model phase

The length has been designed to be projectizable between 700 and 4,000 meters depending on terrain size and slope. For this purpose, the required average terrain slope should be at least 7% (4°). Track installation is carried out to conform as much as possible to the terrain's topographic structure. The terrain can be reconfigured where necessary. Turn radii vary between 4 and 9 meters in accordance with standards and speed. The driving performance is maintained at the highest level with the calculated appropriate angle. Ridge and valley track designs are intended to create different experiences. When designing, natural beauty on the terrain is preserved as it exists. Tunnels and bridges can be designed where necessary, aiming for minimum intervention in the natural structure.

Figure 4. Trail Coaster rail course work

Ergonomically designed vehicles can be used by one person or two people. Children aged 3 and above can use them with an adult, while children over 8 years old can use them alone.  

Figure 5. Trail Coaster vehicle user view

A special braking system allows users to operate the system at their desired speed. With a special braking system that automatically transitions to the braking position when not engaged, vehicles can only be accelerated with deliberate intervention. Vehicles are equipped with 4 and 2-point special safety belt systems. It is not possible to open the safety belt while the vehicle is in motion. The automatic clutch prevents vehicles from exceeding the maximum speed of 40 km/hour as defined in standards. Trail Coaster vehicles, completed in design with energy-absorbing shock buffers, can be ordered in desired colors. The Trail Coaster system is a complex system consisting of tracks, vehicles, exit conveyor, signaling system (automation) and station building.

Exit Conveyor and/or Vehicle Lift

It enables vehicles to be transported to the upper level with users or without users in a suspended state. It can be designed up to 40% (22°) slope. The upward speed can be adjusted according to the desired operating capacity.

Signaling System (Automation System)

A system that controls vehicles moving on the track, provides the operator with real-time information about vehicles, and ensures that vehicles approach each other at low speeds if users neglect to brake. The automation system ensures maximum operating capacity is maintained in the safest manner.

Station Building

The station building, designed in dimensions appropriate to the project size, includes a platform for users to board and alight from vehicles and the operator conveyor. A storage area, vehicle winch and maintenance area are also provided.

Track System

The track system, manufactured from stainless steel, incorporates all fatigue and thermal deformation calculations in the design. In the entertainment vehicle sector where user safety is the most important criterion, track engineering calculations are designed down to the finest details. The necessary measures to prioritize not only user safety but also environmental safety are calculated with great care. An automatic braking system that ensures separation of vehicles on the track is optional. With the automatic braking system, vehicles cannot approach each other more than 40 meters on the track.   Figure 6. Trail Coaster vehicle user view               Acknowledgments We extend our gratitude to our R&D Director Ali Cansun and Polin Waterparks, who supported this work from the beginning.