The advent of internet of things (IoT) technology has ushered in a new dawn for the digital realm, offering innovative avenues for real-time surveillance and assessment of the operational conditions of intricate mechanical systems. Nowadays, mechanical system monitoring technologies are extensively utilized in various sectors, such as rotating and reciprocating machinery, expansive bridges, and intricate aircraft. Nevertheless, in comparison to standard mechanical frameworks, large amusement facilities, which constitute the primary manned electromechanical installations in amusement parks and scenic locales, showcase a myriad of structural designs and multiple failure patterns. The predominant method for fault diagnosis still relies on offline manual evaluations and intermittent testing of vital elements. This practice heavily depends on the inspectors’ expertise and proficiency for effective detection. Moreover, periodic inspections cannot provide immediate feedback on the safety status of crucial components, they lack preemptive warnings for potential malfunctions, and fail to elevate safety measures during equipment operation. Hence, developing an equipment monitoring system grounded in IoT technology and sensor networks is paramount, especially considering the structural nuances and risk profiles of large amusement facilities. This study aims to develop customized operational status monitoring sensors and an IoT platform for large roller coasters, encompassing the design and fabrication of sensors and IoT platforms and data acquisition and processing. The ultimate objective is to enable timely warnings when monitoring signals deviate from normal ranges or violate relevant standards, thereby facilitating the prompt identification of potential safety hazards and equipment faults.

Recent advances in roller coasters accelerate the creation of complex tracks to provide stimulation and excitement for humans. As the main load-bearing component, tracks are prone to damage such as loose connecting bolts, paint peeling, corroded sleeper welds, corroded butt welds, reduced track wall thickness and surface cracks under complex environments and long-term alternating loads. However, inspection of the roller coaster tracks, especially the high-altitude rolling tracks, is a crucial problem that traditional manual detection methods have difficulty solving. In addition, traditional inspection is labor-intensive, time-consuming, and provides only discrete information. Here, a concept of the multifunctional detection robot with a mechanical structure, electrical control system, camera, electromagnetic ultrasonic probes and an array of eddy current probes for detecting large roller coaster tracks is reported. By optimizing the design layout, integrating multiple systems and completing machine testing, the multifunctional roller coaster track detection robot exhibits outstanding performance in track appearance, thickness and crack detection. This study provides great potential for intelligent detection in amusement equipment, railcar, train and so on.

Autonomous vehicles, submersible robotic systems and drones, and other human-carrying equipment consistently adhere to a safety perimeter, ensuring collision-free navigation amidst surrounding objects. In contrast, roller coaster vehicles, despite being constrained to a predetermined track, necessitate frequent safety distance detection owing to the variability introduced by trees and decorative installations. Passengers’ limbs may protrude beyond vehicle boundaries, posing a collision hazard. The motion range of limbs, influenced by vehicle-specific conditions, mismatches standardized safety volumes (cylindrical, cubic, and rectangular) designed for mobile entities. The roller coaster industry’s current practice involves a moving safety frame, which visually inspects for collisions to assess safety distances, which is cumbersome and prone to oversight in intricate settings. Therefore, this study introduces a novel safety envelope detector (SE-detector). It creates a customer-defined virtual safety envelope around the roller coaster vehicle and measures the safety distance based on LiDAR (Light Detection and Ranging) to detect the intrusions of obstacles. Meanwhile, this SE-detector also innovatively integrated an accelerometer to synchronously measure the acceleration of the vehicle. The measured acceleration will be aligned with simulated sequences by dynamic time warping (DTW) algorithms to pinpoint intrusion location. Additionally, a wide-angle camera is also deployed to enhance perception of the surrounding environment. The SE-detector developed in this study has the capability to record inspection results. It is expected to enhance the inspection capabilities of the safety envelope for roller coasters, thereby improving the efficiency of safety distance inspection.