A “Sensitive” Topic

By , October 27, 2017
Robert Cybulski

Hello Again!

The shop has been extra busy the past two weeks as the current set of trains is nearing completion and we are preparing for shipping. One of the final tasks before the trains can be shipped is installing the multiple lapbar monitoring systems. Many Millennium Flyer trains do not feature any type of electronic lapbar monitoring; however, every customer is unique and has different requirements.

This particular set of trains actually features two individual sensors for each lapbar. The first of these sensors is located in the lapbar can (the housing for the restraint locking mechanism), while the second is located near the floor in the center of the rider compartment. These sensors, called inductive proximity sensors, use a magnetic field to determine when a metal object is present. In our case, certain metal parts of the lapbar system move in front of the sensors only when the lapbar is locked.

Near the end of last week, Jase, our engineer in Sunbury, showed me how to correctly install and position the sensors such that they would only trigger when the lapbar is in a locked position. It can be a pretty tedious and difficult task because the sensors only have a range of between 2-4 mm, leaving little room for error. At first, I was pretty slow with installing the sensors; however, I quickly began figuring out the tricks to aligning them correctly. By quitting time Friday, Jase and I were able to finish installing sensors on all but three cars of the first two trains. I spent most of the past two days installing all the sensors for the 3rd and final train.

Although it was a difficult and, at times, frustrating job, I took pride in really owning the task and making sure everything was installed correctly. With that being said, I will definitely enjoy a break from the sensor life.

Until next time, thanks for reading!

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Getting Started

By , October 18, 2017
Robert Cybulski


My name is Robert Cybulski and I am one of GCII’s newest interns! I am a 5th-year (yeah I’ve been in school too long) mechanical engineering student from the Rochester Institute of Technology (RIT). I started my internship at the beginning of September and will be here through the end of December (at which point I will return to school to finally finish my degree).

Going into this internship, I really didn’t know what to expect. After a couple weeks, I still never really know what to expect because every day is a different experience! Although there have been many side-tasks and random trips to pick-up/drop-off parts, our main job has been helping Dan and Todd in the train shop. We are currently working on finishing up a set of trains for an unannounced coaster opening somewhere on planet Earth in 2018.

The beginning of the internship started kind of slow since we were waiting on parts to arrive to finish the trains. This resulted in various smaller tasks such as assembling seat components, restraint locking components, gluing floor mats to floorboards, etc… However, as the trains get closer to completion, work has picked up and I’ve gotten the chance to really get into actually adding parts to the chassis. This past week (actually 2 weeks ago by the time this is posted) I installed guide wheel weldments, brake fins, and anti-rollback (ARB) systems on 8 cars of one of the trains. It was amazing getting to actually add components to trains that will some day ride the tracks of a roller coaster, thrilling hundreds of people daily.

That’s all for now! I will do my best to write often with interesting posts and updates on our progress. Thanks for reading!

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