The installation and dismantling of mechanical amusement equipment (such as roller coasters, carousels, Ferris wheels, etc.) is a key step in ensuring the safe operation and secondary utilization of the equipment, involving knowledge of structural mechanics, mechanical principles, safety regulations, and other aspects. The following provides a detailed explanation from four dimensions: installation process, disassembly process, core safety regulations, and common problems:
1、 Installation process of mechanical amusement equipment
Installation must strictly follow the logic of “preliminary preparation → foundation construction → main assembly → system debugging → acceptance” to ensure the stability of equipment structure and safe operation.
1. Preparation before installation
Site survey and planning
Check the equipment design drawings, confirm the site dimensions (such as the turning radius of the roller coaster track, the diameter of the carousel), ground load-bearing capacity (the concrete foundation needs to meet the equipment’s own weight+maximum load pressure, usually ≥ 20MPa), power supply (voltage and current stability), water source (such as the water circulation system for rushing rapids), and drainage conditions (to avoid water accumulation and corrosion of equipment).
For example, the support foundation of a roller coaster needs to be deeply buried underground, and the concrete strength grade should not be lower than C30 to prevent tilting due to vibration during operation.
Equipment and data verification
Open the box and inspect whether the equipment components are complete (refer to the packing list), whether there is any transportation damage (deformation, cracks, etc.) to key structural components (such as welds, pins, bolts), and whether precision components (such as sensors, hydraulic valves) need to be checked for sealing status.
Organize technical materials: installation manual, electrical schematic diagram, structural assembly diagram, safety specifications (such as GB 8408-2018 “Safety Specification for Large scale Amusement Facilities”), ensure that installation personnel are familiar with equipment parameters (such as rated speed and load-bearing limit).
Personnel and tool preparation
The installation team needs to have special equipment installation qualifications (such as the “Special Equipment Installation, Renovation, and Maintenance License” issued by the State Administration for Market Regulation), and personnel need to undergo special training (familiar with equipment structure, lifting specifications, and emergency response).
Prepare specialized tools: lifting equipment (cranes, forklifts, matching equipment weight, such as 10 ton equipment requiring ≥ 15 ton cranes), torque wrenches (ensuring bolt pre tightening force meets requirements), level gauges (calibrating equipment levelness), insulation testers (testing circuit insulation), etc.
2. Core installation steps
Basic fixation and calibration
Position the embedded parts (such as bolts and steel plates) according to the drawings, pour the concrete foundation (the curing period should meet the strength requirements, usually ≥ 28 days).
When connecting the equipment body to the foundation, calibrate the levelness with a spirit level (such as the horizontal deviation of the carousel table being ≤ 2mm/m), and tighten the fixing bolts (apply anti loosening glue to avoid loosening during operation).
Main structure assembly
Assemble in the order of “from bottom to top, from main to secondary” (such as installing the column first and then the wheel disc on a Ferris wheel), and use specialized lifting equipment during lifting (to avoid direct contact of steel wire ropes with structural components causing wear), and the lifting points must be consistent with the design drawings (to prevent structural deformation).
The connecting parts (such as pins and flanges) need to be cleaned of burrs and lubricated with grease (such as lithium based grease) to ensure flexible rotation and no jamming.
Installation of transmission and control system
Transmission system (motor, gearbox, chain/belt): The axis of the motor should be coaxial with the axis of the driven shaft (deviation ≤ 0.1mm/m), the tension of the chain should be moderate (usually 1%~2% of the span), the pulley should be aligned (deviation ≤ 1mm), and the protective cover should be checked for firmness.
Control system (PLC, sensors, operation console): The circuit wiring should be marked according to the drawing (to avoid misconnection), the signal line should be separated from the power line (to prevent electromagnetic interference), the emergency stop button should be connected in series in the control circuit, and the action should be reliable (the equipment will stop immediately after pressing).
Installation of safety devices
Protective device: The height of the guardrail should be ≥ 1.1m (to prevent personnel from falling), and the safety distance (such as the distance between equipment moving parts and fixed objects should be ≥ 500mm) should meet the requirements.
Restraint devices: safety belts (breaking force ≥ 6kN) and safety bars (gap ≤ 30mm after locking) need to be tested one by one to ensure that they do not loosen during equipment operation.
Warning device: overspeed alarm and limit switch (such as the upper limit position of the hoist) need to be adjusted to trigger sensitivity (such as immediately alarm and stop the machine when overspeed reaches 10%).
Debugging and acceptance
No load debugging: Run for 3-5 cycles, check for any abnormal noise (such as gear meshing), vibration (amplitude ≤ 0.1mm), oil leakage (hydraulic system), etc., and record operating parameters (such as speed and current).
Load debugging: Conduct tests at 50%, 100%, and 125% of the rated load (short-term overload test) to verify equipment stability (such as roller coaster track stress ≤ 80% of the design value).
Third party acceptance: Invite special equipment testing institutions to conduct type tests, issue qualified reports, and apply for a registration certificate with the local market supervision department before putting it into operation.
2、 Dismantling process of mechanical amusement equipment
Disassembly should avoid equipment damage (affecting secondary installation) and safety accidents, with the core principle of “reverse installation process and classified protection of components”.
1. Preparation before disassembly
Plan formulation: Based on the equipment structure (such as the division of detachable units), formulate the dismantling sequence (such as dismantling the track first and then dismantling the bracket for roller coasters), clarify the responsible person, tools, and precautions for each step (such as wearing a safety belt for high-altitude operations).
Equipment status inspection: Record equipment operating defects (such as abnormal noise from a certain bearing), and focus on inspecting the component during disassembly; Release the pressure of the hydraulic/pneumatic system (if the hydraulic cylinder needs to return to its initial state), drain the coolant/lubricating oil (to avoid leakage and contamination).
On site protection: Set up a warning area (with warning lines and signs) and prohibit unrelated personnel from entering; Prepare component storage racks (classified and placed to avoid squeezing), packaging materials (such as bubble wrap, wooden boxes, to protect vulnerable parts such as glass and sensors).
2. Disassembly core steps
Dismantling of accessory components
Remove non structural components first: decorative parts (lightboxes, cartoon shapes), safety devices (seat belts, guardrails), operation consoles, etc., and label them accordingly (such as labeling “left column decorative panel”).
Disassembly of control system and transmission system
Remove the circuit after power failure: first disconnect the main power supply, then remove the control line (record the wiring method with a photo or drawing for easy reinstallation). The motor, sensor, etc. need to be separately packaged (the motor shaft needs to be coated with anti rust oil).
Transmission components: Before disassembling the chain/belt, the meshing position should be marked (to avoid wrong teeth during reassembly), the gearbox should be sealed at the oil inlet (to prevent debris from entering), and the bearings should be coated with anti rust grease and wrapped in plastic bags.
Dismantling of main structure
Disassemble in the reverse order of installation (such as dismantling the wheel disc first, then dismantling the Ferris wheel column), and use special tools (to avoid slipping) when disassembling bolts. If the bolts rust, apply loosening agent (such as WD-40) and let them stand for 10 minutes.
When lifting large structural components (such as roller coaster track sections), a sling is required (to avoid scratching the surface with steel wire ropes), and after lifting, it needs to be temporarily fixed on the transport frame (to prevent shaking and collision).
Component inventory and transportation
Check the quantity of components (such as bolts and pins) according to the list, inspect for any damage (such as cracks or deformations), and record it in the “Equipment Status Table”.
During transportation, precision components such as control cabinets and sensors need to be loaded separately (to avoid heavy pressure), and metal structural components need to be cushioned with wooden blocks (to prevent friction and corrosion during transportation) and fixed inside the carriage (tightened with steel wire ropes to avoid displacement).
3、 Key safety and regulatory requirements
Personnel qualifications: Installation/dismantling personnel must hold a “Special Equipment Operator Certificate” (for the project of “Installation and Maintenance of Large Amusement Facilities”), and participate in safety training every year.
On site safety: High altitude operations (≥ 2m) require wearing safety belts and setting up scaffolding; Electrical work requires wearing insulated shoes and gloves; Lifting operations require a dedicated person to command (holding a lifting command certificate), and lifting equipment must be regularly inspected and qualified.
Regulatory basis: It must comply with the Special Equipment Safety Law and the License Rules for Installation, Renovation, and Maintenance of Large scale Amusement Facilities. After installation, it is necessary to register its use with the regulatory department within 30 days, and report to the regulatory department before dismantling (especially for moving equipment).
4、 Common problems and solutions
Excessive vibration during operation after installation: it may be due to uneven foundation (recalibration of levelness) or loose bolts (re tightening according to torque requirements).
Component jamming during disassembly: If the pin shaft cannot be pulled out, it can be heated (by evenly heating the structure around the pin shaft with a spray gun and using the thermal expansion and contraction gap to remove it), and cannot be forcefully knocked (to avoid structural deformation).
Circuit short circuit: During installation, it is necessary to check whether the insulation layer of the wire is damaged and whether the wiring terminals are tightly pressed (using an insulation tester to detect insulation resistance ≥ 1M Ω).
