Precision Stage Automation System – 26-Axis EtherCAT-Controlled Rigging Solution

Rotem Segev
41 minutes ago
3 min read

Revolutionary Control Meets Theatrical Excellence

Segev Technologies proudly presents a state-of-the-art 26-motor stage rigging system that combines industrial-grade precision with intuitive control. Designed and implemented for a premier performing arts venue, this installation delivers ±1 cm positioning accuracy with complete flexibility for:

Pre-programmed shows
Day-to-day setup and focusing
Real-time manual operation during rehearsals

Mechanical design, building, commissioning and theatre infrastructure: Charmer Group LTD.

System Architecture: Where Precision Meets Performance

At the heart of the system is a Beckhoff industrial controller orchestrating 26 Mitsubishi variable-frequency drives (VFDs) over high-speed EtherCAT.

This architecture provides:

Deterministic, real-time motion control
Microsecond-level synchronization between all motors
Smooth, coordinated movement of multiple battens and scenic elements

Key Technical Highlights

Motion System

26 independent motorized winch axes
Positioning accuracy: ±1 cm
Closed-loop speed and position control
Synchronized multi-axis motion for complex cues

Control & Power

Beckhoff PLC platform with EtherCAT fieldbus
26 Mitsubishi VFD inverters
Industrial power distribution with clear labeling
Organized cable management for easy maintenance
Integrated hard-wired emergency stop and safety circuits
Load monitoring on each axis for overload protection

Three Operating Modes for Complete Flexibility

1. Show Mode – Pre-Programmed Excellence

Store and replay complex movement sequences with perfect repeatability.Entire productions can be programmed in advance, including:

Target positions
Acceleration and deceleration profiles
Timed, synchronized multi-axis moves

Ideal for recurring shows where every cue must hit the same mark night after night.

2. Position Mode – Absolute Accuracy

Direct position control for setup and technical work:

Select any axis and send it to a desired height
Use stored presets for trims of LX battens, legs, borders and screens
Closed-loop control ensures that target positions are reached and held, even under changing loads

3. Speed Mode – Real-Time Manual Control

For hands-on work and rehearsals, Speed Mode allows:

Joystick-based up/down control
Variable speed with smooth acceleration and deceleration
Full safety supervision while the operator “drives” the rig in real time

Operator Interface: Built for Stage Technicians

The custom operator desk puts complete control at the technician’s fingertips.

Dual-Screen Visualization

Real-time overview of all 26 axes
Vertical “fader” style position display for each motor
Color-coded status (ready, moving, limits, warnings)
Clear indication of top/bottom limits and current height

Physical Control Panel

Industrial joystick for manual motion
Dedicated mode-selection buttons (Show / Position / Speed)
Illuminated push buttons and selector switches
Prominent hard-wired emergency stop mushroom

Touchscreen Interface

Direct access to individual axes
Quick selection of presets and trims
System diagnostics and status pages

Safety: Engineered Without Compromise

Lifting heavy loads above performers and audiences demands the highest safety standards. This system was designed with multi-layer protection:

Hard-wired emergency stop circuits
Software and hardware travel limits on every axis
Mode-dependent speed limits to protect scenery and equipment
Continuous status monitoring and clear visual feedback
Real-time load and current monitoring to detect overloads or snags before they become dangerous