Contents

Acknowledgments

Chapter 1:Moving Stuff on Stage

Manual vs. Mechanization vs. Automation

Advantages of Automation

Disadvantages of Automation

Thinking Top-Down, Designing Bottom-Up

Jump In – This Stuff Is Fun!

Chapter 2:Pentagon of Power: Breaking Up Automation into Five Parts

Operator Interface

Control Circuit

Amplifier

Machine

Feedback Sensor

Using the Pentagon of Power as a Map

Summary

Chapter 3:Welcome to the Machine(s): A Survey of Common Theatrical Machines

A Mechanical Primer

Common Components

Winches

Turntables

Hoists

Lifts

Roll Drops

Turtles

Wrap Up

Chapter 4:Motivating a Machine

Electric Motors

Hydraulics

Pneumatics

Summary

Chapter 5:Powering Motors and Actuators

Four-Quadrant Control

Variable Frequency Drives (VFDs)

DC Regen Drives

Brushless Servo Drives

Stepper Drives

Variable-Speed Hydraulic Pumps

Proportional Valve Drives

Chapter 6:Sensing and Measuring Motion

Limit Switches

Proximity Sensors

Incremental Encoders

Absolute Encoders

Chapter 7:Simple Control

Switches

Potentiometers

Relays

Putting It All Together

Summary

Chapter 8:Programmable Logic Controllers (PLCs)

What Is a PLC?

Advantages of PLCs

Types and Sizes of PLCs

Programming the Programmable Logic Controller

Disclaimer

Climbing the Ladder

Scanning

Chapter 9:Motion Control with a PID Loop

Encoders

What Is PID?

Examples of PID Controllers

Detecting Encoder Failures and Obstructions

Command Signal Formats

Putting It All Together

PID Tuning Tips

Chapter 10:Safety

Risk Assessment

Safety Standards

ESTA Technical Standards Program

ANSI E1.43: 2016 Entertainment Technology – Performer Flying Systems

ANSI E1.42: 2016 Entertainment Technology – Design, Installation, and Use of Orchestra Pit Lifts

Failsafe Concept

Redundancy

Emergency Stop

Safety Sensors

Interlock to Avoid Danger

Wrap Up

Chapter 11:Operator Interface

Configuration

Status Information

Jogging

Recording Cues

Executing Cues

Aborting Cues

Logging

Commercial Systems

Options for Rolling Your Own

PLC HMI

Windows, Mac OS, or Linux Application

Common Cueing Challenges and Solutions

Wrap Up

Chapter 12:Networks

Bits and Bytes

Networks in General

Serial Communication

RS485

Ethernet

Industrial Network Protocols

EtherCAT

Proprietary Application Protocols

Tower of Babel

Final Thoughts on Networks

Chapter 13:Integrating with Other Systems

DMX

SMPTE Timecode

Art-Net

sACN

OSC

PosiStageNet

Custom UDP Protocols

Chapter 14:Implementation

Qualified vs. Competent

NEC and UL508A Standards

Diagrams and Schematics

Wire and Cable

Plugs and Connectors

Grounding and Fusing

Panel Fabrication and Wiring

Tools of the Trade

Wrap Up

Chapter 15:Resources for Learning More

Machinery

Amplifiers

Feedback Sensors

Controls

Safety

Operator Interface

Control Networks

Integration Networks

Implementation

Good Luck!

Notes

Index

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