Sky-High Amusement Ride Safety at Prater Tower

Prater Tower Profile: Key Highlights and Safety Features of the World's Tallest Chain Carousel

• What was needed: An energy chain of the Series E4.1, chainflex® cables
• Requirements: The pipes must be routed safely and reliably at a height of 70 meters - in all weather conditions
• Industry: Amusement Rides
• Success for the customer: The chain links are checked every day, and no problems have been noticed so far. "The energy chain is a safety-relevant component, and we can fully rely on it"

The Safety Challenges of Amusement Rides: How Prater Tower Overcomes Height and Maintenance Risks

Even before the ride starts, Franz Taraba moves between the two-seater gondolas hanging just above the ground. As the technician of the Prater Tower, he checks the seat belts on passengers and secures the additional metal bracket. Safety is paramount at the Prater Tower, given the ride's impressive dimensions: the tower stands at 117 meters, with a maximum flight height of 95 meters. The StarFlyer chain ride, created by Austrian manufacturer Funtime Industries, reaches speeds of up to 60 kilometers per hour, giving visitors a thrilling experience above the rooftops of the Prater and a panoramic view of Vienna's skyline, from the Danube Tower to the city center. Even spectators below are captivated by the ride's spectacle, especially as the gondolas begin to ascend and rotate.

Initially, the gondolas are pulled to a certain height before the rotation starts, and physics takes over, causing passengers to be carried outward. The seats are suspended from taut steel chains connected to the tower. A ride in the Prater Tower delivers an adrenaline rush unlike any other. Yet, what many don’t see is the sophisticated technology that makes the ride possible. Within the limited space of the tower, a ladder, steel cables, and other critical components ascend to lofty heights. One key component for smooth operation is located in the tower's outer framework: a suspended energy chain from Cologne-based motion plastics specialist igus®, housed within a metal guide rail.

When Funtime erected the tower at Vienna's Prater in 2010, the StarFlyer was a world first, setting new records for its scale. It even received a Guinness World Record certificate as the highest chain carousel in the world, proudly displayed under the ride. Since then, Funtime has installed other, sometimes even larger, StarFlyers worldwide, including in Orlando, USA, and Texas. The construction of the Prater Tower involved 30,000 screws, and its foundation alone weighs 720 tons. To withstand the immense loads at such heights, seamless coordination between human oversight and technological components is essential. Franz Taraba is in the tower daily, inspecting all parts to ensure a safe experience for every visitor. "We perform a visual inspection of the tower every day," Taraba explains. Typically, there is nothing to report, and the ride is ready for another day at the Prater.

The reliability of the technology owes much to the high quality of materials used, such as the igus® energy chain, which plays a crucial role in ensuring the smooth and safe operation of the ride.

Innovative Safety Solution: How igus® Energy Chains Keep Prater Tower Running Smoothly

When the Prater Tower was designed over 13 years ago, an energy chain system was chosen for its energy supply. The plastic components of the chain have proven ideal for amusement park applications: they safely route cables without damage, ensure smooth traversing movement, and withstand harsh weather conditions due to their prominent placement. "The igus® energy chain runs like clockwork," says Robert Danhel, technical manager at the Prater Tower. A major benefit of the energy chain is its lubrication-free operation, reducing maintenance.

igus®'s lubrication-free plastic components, including energy chains and plain bearings, have decades of proven reliability. For the Prater Tower, Funtime and igus® installed a full-bar E4.65 series energy chain during construction, which has been operating reliably ever since. "We still have the same energy chain as on day one," says Danhel.

The energy chain supports an 80-meter travel distance, guiding gondolas up at a speed of 2.2 meters per second. Suspended several meters above the ground, it ensures secure, flexible movement, with chainflex® cables maintaining communication from top to bottom. These chainflex® cables, designed specifically for energy chain use, play a critical role, handling power, data, and monitoring functions. "We've had no issues with the chainflex® cables either," Danhel adds.

Alternative solutions, such as busbars, were dismissed due to reliability concerns in data transmission and weather resistance, which would require greater maintenance. The choice of igus® energy chains has stood the test of time, providing a reliable and efficient solution.