Stage Automation

Stage Technologies Automation User Generated Handbook

Hardware

There are three items of hardware that we use.

• The Illusionist Desk [See section title 'Desk Hardware']
• The MCC (Motor Control Cabinet)
• 4x BigTow200 Motors

We also have:

• 4x Spreader Beams
• 8x Spreader Beam Clamps
• 4x External ESTOPS

All of this hardware is designed and built by Stage Technologies.

For details of the Motors visit this link: [1]

Motor Control Cabinet [Front]

• Rotate Power switch to turn both ON and OFF
• Always make sure that the ESTOP jumper is connected to the next available port. This is because the ESTOP system runs in Parallel
• Only one Motor can be selected at a time when being used in Local Control
• Hold down the BLUE button and either UP or DOWN to move in Local Control
• Hold down the RED 'FAST' button as well to make the motor move quicker
• Always remember to switch back to Remote when finished using Local Control
• When running an axis in after moving the motor, always use Remote control from the desk because Errors [Such as a Cross Grove] can not be rectified in Local Control.

Motor Control Cabinet [Rear Connections]

Big Tow200 Motor Connections

• Always remove the Encoder and ESTOP/Power cables when moving the motors
• Always leave MSPEC on when moving motors to prevent possible crushing
• Before removing any connectors always ensure that both the Illusionist Desk and the MCC are powered off to prevent Errors.

Moving The Big Tow200 Motors

• To slide the motor along the spreader beam loosen the machine screws at the five points on either side of the motor.
• Always wear steel toecaps when moving the motors.
• Try to have two people at each end of the beam and two people around the motor when moving the motor.
• Remember to lift the beam and not the motor and lift do not slide.
• Only loosen the machine screws
• BE VERY CAREFUL OF THE COUNTERWEIGHT LINES AS YOU MOVE THE BEAMS

Desk Hardware

The desk we use for the Automated Flying system within the Academy is the Illusionist Desk.

The controls for the desk

• A flat panel display screen
• 58 command keys on the right hand side of the console
• A compact external keyboard
• 3 E-Belt playbacks (far left red,then blue and yellow) each with go/stop and select keys
• An emergency stop button
• A touch pad with left and right mouse buttons
• A single adjustable desk light
• A writeable CD Rom drive
• There is a mountable rack
• A single deadman's handle situated below the playbacks

With the deadman's handle it is essential it is pressed and held down before amove and kept pressed down for the duration of the move.

Constraints imposed by the hardware

• Not designed to be portable
• Does not have a touch screen
• There is no duplicated computer hardware
• The illusionist only has three playbacks so it would be impossible to create a cue that would

require five playbacks.

Using Playbacks

Playback works in two different ways, Joystick and Speed. On our desk there no up and down keys so the E-belt is used to change both the seep and direction.

Selecting a Playback

Each playback has a select button which is situated above the E-Belt.Only one playback is active at one time, so when a command is entered it will be applied to all axes on the selected playback.

NB When the playback is selected the select button is amber and blue when inactive.

• Icons for Select Button

Tick - This means the playback is selected

Cross - This means the playback is not in use

Start/Stop Button

The button below each playback is a mulit-functional button for both start and stop. The button will read the action that is taking place, i.e if the button states 'stop' all axes will be stopped on that playback.

NB The dead mans handle must be pressed to start any movements.

• Icons for Start/Stop Button

GO - Pressing this will start any movement

STOP - Pressing this will stop any movement

TIMER ICON - This indicates that the playback is busy and the operator must wiat till the operation is complete

Changing speed

In speed mode the E-belt is used to alter the speed of the assigned axes. The playback will be set at 100% by default, meaning the axes will move at their plotted speeds. The plotted speeds can be altered, using the E-belt can slow or spees up the move. The system can determain that no axes will exceed its maximum speed. So as long as the plooted speed of the axes on the playback is not more than 50% of the allowed maximum the speed can be increased to 200%.

Dead Man's Handle

The Dead Man's Handle (DMH) acts as a safety device, which prevents any accidental movements of axes when the operator is not present. As metioned, before the Start/Stop buttons can initiate any movement the DMH has to be pressed. If the DMH is released all axes being controlled will be brought to a safe and controlled stop. It needs to be noted that the DMH should only be held down by hand, not weighted or taped down when moving any axes. It is also the operators responsibilty to make sure the DMH is in correct wroking order.

Emergency Stops

Our system has a number of Emergency Stops (E-Stops). These are used to in the case of an emergency and will stop all motors in the system. An E-Stop switch cuts all power to the system, normally after a short interval the E-stop brings all axes to a fast but controlled stop. After the interval, normally 1 second all power is cut and the brakes are applied to all the motors. When resetting the system it would normally take 10 seconds. To operate the E-Stop the switch is pressed down until it latches. The switch is twisted clockwise to release it. Movement has to resume for the E-Stop to reset.

Command Keys

Axis is a resource command. When pressing the axes key it allows the operator to add or remove a selected axes from a playback or to apply specific properties to the selected axes (accel,decel,speed). The axis key must be illuminated amber when wanting to reference.

Group is a resource command. This key allows you to load groups onto a playback, or specify particular properties (accel,decel,speed). The group key must be illuminated amber before referencing.

Action is a resource command.This key is used to load an action onto a selected playback. When loaded to a playback it overrides any exsisting instructions on the selected playback with action.

VCAtion is a resource command. When the action key is pressed twice this allows the operator to load a previous Visual Creator Acton on the selected playback. Loading a recorded VCAction overrides any existing instructions on the selected playback with VCAction.

State is a resource command. This key loads a state from a current show. In performance mode this is the default command.

Macro is a resource command. Pressing this key allows the operator to load a specific macro onto a selected playback. The macro will be executed when the playbacks 'Go' button is pressed.

Define, Rig and Reference Scenery

Once you have physically rigged your scenery you will need to soft rig the scenery on the desk. The process for doing that is:

1) [SHOW] [001] [RECORD] - You need to record a new show before you can rig scenery.

2) [RIG]

You now need to define which axis you are rigging and what is on it.

3) select "Define Scenery" Tab

4) Select the Axis/Axises you want to rig (using [Ctrl] key on keyboard to select more than one)

5) Select whether it is a "Single Axis" or "Multi Axis"

• If you select "Multi Axis" you will be given the option of what kind of group to make it: Safe, Locked etc. You will also be asked to give it a "Group Number" and "Master Axis". The Master Axis is the Axis the height for your reference possition is taken from, it is used most effectivly on groups where the axis' are at different heights eg. for a slanting roof.

6) Select "Rig/Derig Scenery" Tab

7) Select Axis, Click "Rig" then "Reference" 99% of the time you will reference to 0m

Referencing

The act of referencing is done to give a point of reference to the size of the piece of scenery being flown. A reference point would normally be set with the scenery just touching the deck. You would then plot your deads. Should the piece of scenery change size - a drop stretching, a doorway shortened/extended instead of changing each dead individually you can change the reference point and all the deads will automatically be adjusted. Very useful if you have an indecisive designer or multiple deads.

N/B You can only change your reference point if you have manualy set your reference point. If you have auto referenced you can not change your reference point.

Control of Axis

Each axis can be moved easily without having to group or reference them first. To move a single axis-

1. select the playback you want to use by pressing the button above it, the yellow tick should appear
2. Select which axis you wish to move- [Axis] (1)
3. Enter the height to which you want the axis to move- [pos] [5000]
4. If necessary select the time in which you want the move to be completed in- [time] [10]
5. Hold down the DMH
6. Press the button below your selected playback so that the (go) message appears

• The speed at which the axis is travelling can be increased or decreased by using the E belt
• The DMH must be held down until the move is completed
• In order to stop the move before it is completed press the button below the playback so that it shows the (stop) message
• In order to move more than one axis, at point 2 enter- [Axis] (1) [->] (4)
• To clear the playback and begin a new command- [enter] [enter]

Automation Cue Sheet

Automation Cues

Triggers

A Trigger is used to start an action on another axis when one axis reaches a certain speed or position. A Trigger can be set using the [MORE] menu.

A Trigger can only be set when the triggered axis's and the triggering axis are set on different play backs.

Safety

There are many safety aspects to consider when operating and adjusting the illusionist stage automation system. When moving the motors-

• The orange grid lights should be switched on before any work on the grid is undertaken.
• Ensure that there are enough people present to lift the motors, ideally 6.
• Always wear steel toe caps when moving the motors.
• Use slings passed through the spreader beams to adjust their position.
• Plan your path and ensure that all obstacles (including counterweight steels) are out of the way.
• Appoint one person to communicate to the others when and how the motors are being moved.
• Always re affix the clamps to the spreader beams once the motor has been positioned.
• Tighten the machine screws if the motor itself has been moved.
• Always disconect the power and encoder cables before moving motors and place well out of the way, idealy hanging to provent damage to the conectors
• Never disconect the Mspec as it has a tendancy to get caught under the motor and spreder beam and crushed!

When operating the the illusionist desk-

• Ensure that everyone on stage is aware of any potential axis movements.
• Where possible ensure that the desk operator has a clear view of the axis and item to be flown.
• When possible and especially if the operator does not have a clear view of the axis, other individuals should be used to spot the axis.
• E-stop buttons should be run to the position of these individuals.
• Each E-Stop that is in use should be tested before the start of each performance and reset afterwards.
• The operator should run through each state before shows to make sure all is in working order and there are no errors.