I've been around the Pole Position since it was new, given my history with the Fabri Group. The ride was running on an old Siemens PLC system that was completely outdated. Even in its heyday, the ride could only handle two or three cars on the track at a time before throwing faults. The air system was a maze of stainless steel tubing with manual valves — if there was a problem, the operator had to jump down, run around, open the cabinet, and physically push a valve to release a brake. This rebuild brought the ride into the modern era.
What We Did
New Compact Logic PLC — Complete operating system rebuild with modern Compact Logic PLCs replacing the outdated Siemens system.
New Electrical Cabinets — All-new electrical cabinets with clean, modern wiring.
HMI Operator Stand — New operator stand with HMI screen and a maintenance screen that allows operators to release brakes safely with built-in interlocks.
Ethernet-Controlled Air Brake System — Replaced the maze of manual valves and stainless tubing with a compact Ethernet-controlled air valve block. Just airlines, Ethernet, and a power cable — clean and easy to service.
Built-In Safety Interlocks — The system prevents brake release if there's a car in the zone or block ahead, eliminating the manual safety risks of the old setup.
Improved Fault Recovery — Modern fault recovery system is ten times better than the original, getting the ride back up faster and with less manual intervention.
Project Photos
The Result
The new system more than doubled the ride's capacity. Where the old system was limited to one launch every minute and a half, the modernized Pole Position now runs over 70 launches per hour. One of their best days hit 920 launches in a 13-hour day. Faster recovery, safer operation, and a system that actually keeps up with the crowd.
