This looks really interesting! What's the peak speed, ticks per cart sent through?
Is there an easier way to count ticks then pressing '.' repeatedly and losing count?
The main problem speed wise is the magma refill. I ended up with a 1 wide channel 13 squares long from the magma tube.
In the design I listed at the start, I had 4 carts loaded into it waiting for the 7/7 pressure plate to trigger, 1 in the trench and 3 stacked above it. All 4 slammed through the trench right after it filled, but only 3 of them were full of magma. I expect what that means is that if the trench is full to 7/7 magma, it can fill 2 carts. Which seems to fit with my testing of the (failed) reversed design, opening a door makes the magma next to it drop in half right away
I tried a reversed system (dry first, then magma), and it doesn't work anywhere near as well. I was using dumping zones for testing this time, since setting up minecart routes each time I changed the dump location was a royal pain, ... But the main problem is losing magma depth before the carts have a chance to fill. There also seems be a time or speed requirement, so one needs to be careful to not over accelerate the carts.
More testing reveals that impulse ramps will cause minecarts to gain speed in 6/7 magma and lower. Impulse ramps seem to be able to keep minecarts moving on the level in magma, but can't push it up a level (which we already knew). Possibly they are hitting some maximum speed? However it seems that all your really need is a way to keep the last couple of spaces at 6/7 or lower.
New Improved Design! only 1 magma safe mechanism, and even that's optional!
Well, I'm not counting anything you're using to create a magma drain. I ended up just piping it off the map for this one, since it made testing simpler. The basic setup is just having a 4wide input, and a 1 tile drain to the side of the last ramp, this should keep the first several ramps permanently at 6/7 while the drain is open.
Top view, z0
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MMRw <-- I was dropping on this ramp when testing
wwRw <-- I'd suggest adding this line when building it to drop on a ramp here instead, as I ended up with one cart knocked into the magma input area once
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Top view: z1 (as tested, the open space '.' is over the south most ramp)
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Top view: z2
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Top view: z3
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The 4 input channels (~11 tiles long) coming off the side of my magma pipe were enough to keep the first 4 squares at 6/7 solidly with a 1 wide output. I then had a 4wide path off draining off the edge of the map through fortifications. Other drain systems would work, but since my pipe is right near the map edge that was super easy to setup.
On z1 I have a pressure plate (dry!) that opens the door on z0 when a cart is about to go through the lava (it will still be open when the cart leaves). The door can actually be left out, or manually controlled It's mostly just there so the magma stops flowing if you don't use it for a while.
z2 is just the top of the minecart stack and z3 is the track stop, you can put the stop on z2 (or even z1) safely if you're not using the bridge, since you won't have minecarts stacking up in reach of your dwarfs.
The bridge is optional, I used it to prime 4 carts at once, which makes one gets stuck on the pressure plate when you launch all 4 together, however it does not seem to jam the system and it loaded the other 3 with magma. I'm sure someone has a good quantum cart stack dispenser design on the forums somewhere..... hopefully... For a basic setup I'd just skip the bridge and rely on fact that track stops can only be used by one dwarf at a time. If it does get stuck, you do kinda need to remove the cart, since it defeats the point of the door. Then again, you don't really need the door either if you don't care about magma updates.
Once I ended up with a cart knocked sideways into the magma entrance area, but I've been unable to reproduce it. I'd change the design as I noted in the diagram though just to be safe.