We are delighted to announce the successful completion and commissioning of a brand-new control system for the multi-car Maurer Söhne Mouse roller coaster at Pleasurewood Hills Family Theme Park.

Projects like this are always rewarding, but this one was particularly special. Combining complex ride operations, modern safety requirements, multiple ride zones, and a substantial I/O count, this upgrade represented a true technical challenge from start to finish. Seeing the attraction reopen to guests and operate smoothly has made all the hard work worthwhile.

A Major Modernisation Project

The Maurer Söhne Mouse is one of the park's signature attractions, delivering the sharp turns, sudden drops, and unpredictable ride experience that have made wild mouse coasters a favourite with guests for generations.

Behind the scenes, however, a roller coaster relies on an incredibly sophisticated control infrastructure. Every train movement, brake release, safety check, operator command, and ride status indication must be carefully monitored and controlled to ensure safe and reliable operation.

This project involved the complete development and implementation of a new ride control system designed to meet modern operational standards while improving reliability, diagnostics, and maintainability for the park's engineering team.

Powered by Siemens S7-1500 Fail-Safe Technology

At the heart of the new installation is the powerful Siemens S7-1500F platform.

The S7-1500 fail-safe range is widely recognised as one of the most capable and flexible industrial automation systems available today. Its advanced processing capabilities, integrated safety functions, and extensive diagnostics make it ideally suited for demanding amusement ride applications where safety and reliability are paramount.

Using a fail-safe architecture allows critical ride functions to be continuously monitored and validated, ensuring that the system responds appropriately to any abnormal condition while maintaining the highest levels of operational integrity.

Managing a Complex Multi-Car Ride

Unlike simpler attractions, a multi-car roller coaster requires constant coordination between multiple ride zones and train positions.

The new control system has been designed to manage:

• Multiple ride vehicles operating simultaneously
• Numerous ride block sections
• Continuous train position monitoring
• Automated safety interlocking
• Operator control and ride supervision
• Recovery procedures following interruptions or faults

The complexity of managing multiple vehicles safely across a dynamic ride environment makes block control one of the most critical aspects of roller coaster automation.

Every movement must be verified, every zone status confirmed, and every transition between ride sections carefully controlled.

Extensive Brake Control System

One of the standout elements of the project was the integration and management of nine separate brake zones throughout the attraction.

Brake systems form the backbone of roller coaster safety logic. They are responsible for controlling vehicle movement, maintaining safe train separation, and ensuring that vehicles can be safely stopped whenever required.

The new control architecture continuously supervises all brake functions, providing:

• Real-time brake status monitoring
• Safety interlocking
• Fault detection
• Automatic ride sequencing
• Enhanced diagnostics for maintenance personnel

This level of monitoring significantly improves operational awareness while reducing troubleshooting time when issues occur.

Station Control and Operator Interface

In addition to the ride's brake systems, the project included a complete station control solution designed to give operators clear, intuitive access to ride functions.

A modern 10-inch touchscreen HMI provides a central interface for:

• Ride status monitoring
• Start-up procedures
• Ride operation controls
• Alarm management
• Diagnostic information
• Maintenance functions
• Recovery operations

The objective was not only to modernise the ride's technology but also to improve the day-to-day experience for ride operators and engineers.

Clear visualisation and intuitive controls help reduce training requirements and provide quicker access to important information during operation.

Advanced Automated Checking Functions

A key feature of the new system is its comprehensive automated checking functionality.

Before operation, the control system performs a series of automated validation routines to verify that critical ride conditions have been met.

These checks help ensure:

• Ride systems are correctly configured
• Safety devices are functioning as expected
• Brake zones are reporting correctly
• Communications are healthy
• Operational conditions are satisfied before dispatch

By automating these processes, the system reduces the potential for human error while improving consistency and efficiency during daily ride start-up.

Intelligent Recovery Capabilities

One of the most valuable improvements delivered by the new control system is the implementation of automated recovery functions.

Historically, ride interruptions can require lengthy troubleshooting and manual intervention before operations can resume. Modern control systems aim to minimise downtime by providing intelligent fault handling and guided recovery procedures.

The new platform assists operators and engineers by:

• Identifying fault locations quickly
• Providing detailed diagnostic information
• Automating recovery sequences where appropriate
• Reducing unnecessary downtime
• Supporting faster return to service

These capabilities help maximise ride availability while maintaining the highest standards of safety.

A Significant I/O Installation

Projects of this scale involve managing a substantial amount of field equipment throughout the attraction.

From sensors and limit switches to brake controls, operator interfaces, status indicators, and safety devices, the overall I/O count for the project was extensive.

Each input and output forms part of a larger safety and operational framework, requiring meticulous design, testing, commissioning, and validation to ensure every component performs exactly as intended.

The result is a highly integrated control solution that provides complete visibility and control across the entire ride system.

Collaboration Makes Success Possible

Complex projects like this are never achieved by one individual alone. Successful delivery requires close cooperation between ride operators, engineers, management teams, suppliers, and commissioning personnel.

We would like to extend our sincere thanks to everyone involved throughout the project. The professionalism, support, and collaboration shown by the team at Pleasurewood Hills made the entire process both productive and enjoyable.

Working alongside people who share a commitment to quality and safety is always a pleasure, and this project was no exception.

Seeing Guests Back on the Ride

Ultimately, the most rewarding moment in any ride control project comes when the attraction opens to the public and guests begin enjoying the experience.

After months of design, programming, testing, commissioning, and validation, seeing trains running smoothly and hearing the excitement of riders makes every challenge worthwhile.

This project represented a genuine technical tour de force—combining modern fail-safe control technology, complex ride logic, extensive brake management, advanced diagnostics, and intelligent recovery systems into a single integrated solution.

We are incredibly proud of the finished result and look forward to seeing the Maurer Söhne Mouse continue to thrill guests for many years to come.

A huge thank you to everyone involved—and congratulations on the successful reopening of this fantastic attraction.