So why every time a new PLC is installed they have issues (was the same with Spinball last year). I’m not disagreeing with you just curious.
Have you watched Spinball operating recently?
The mechanical switch, that I assume shows if a car has passed it on the break run just before the station is regularly kicked open by the onload ride host as it doesn’t spring back into a “open” position.
It’s either bad maintenance and/or mechanically not fit for purpose.
Nothing to do with the PLC. Most rides approaching 20-25 years old will get PLC upgrades now. (Unless of course your corkscrew and rely on relay logic or some ancient PLC)
This will be reasonably straight forward whereby the actual processor unit and associated IO hardware will be replaced, and the software simply “added” to the new hardware without any significant changes as they have upgrade paths.
Fundamentally the PLC software, i.e. how the ride works won’t change. As the inputs/outputs haven’t changed in terms of sensors etc. Most rides at Alton, i would have thought, will have “conventional” IO (i.e. Hardwired back to the control panel, rather than intelligent devices (wired via a communication medium)) This makes the upgrades even easier.
Nemesis may be different if it has had software mods to accommodate a new lift hill VSD and changes to the braking system but they aren’t major. That will have had a PLC upgrade as well.
As will many other rides of a similar age, RMT, Rapids, Oblivion. There is more than likely nothing wrong with the kit, they are just no longer supported by the manufacturer for spares etc and are too difficult to maintain as it might need particular software that is also unsupported. Or the staff who know how it works are too old!
This work will be undertaken by a specialist company, probably someone acting on behalf of the manufacturer themselves (Consign AG I believe do a lot, also Amusement Technical in the UK)
I’d be surprised if this was done in house, as I get the impression most of Alton’s staff are electricians with laptops dealing with fault finding rather than “project work” as such which is a different beast. When was the last time you saw a tech turn up to a breakdown with a laptop bag? They just don’t need it.
The software/hardware used for attractions is tried and tested and software principles generally quite basic (although they will be using safety PLCs, compared to something like Pharma, Oil & Gas, Nuclear and Food and Bev)
Coaster trains are generally mechanical beasts with the harnesses released only by hardware in the station floor. Aside from that there’s not a lot to know.
Galactica on the other hand, I get the impression is a different animal altogether. But again without the software, schematics or inside of the control panel it’s hard to tell but I’m sure I’ve seen safety IO onboard the crafts in strip down pictures etc.
Dark rides usually look more interesting from a control perspective, and things like Rise of the Resistance are mind boggling from an engineering perspective.
My takeaway would be don’t mistake the control system acting as it should as a problem, overspeed and underspeeds are an environmental problem. (As we saw Saturday night with Nemesis) Or the the ride stopping due to getting irregular feedback from a redundant proxy sensor.
These aren’t software problems, but the system behaving as it should, reacting to its environment.