Stage Automation, Winches, and Motion Control Systems

This course immerses technicians in the engineering, operation, and maintenance of mechanized theatrical movement systems. Students explore the mechanics of zero-fleet and drum winches, variable-frequency drives, hydraulic actuators, and position feedback sensors including absolute encoders and limit switches. The curriculum emphasizes motion control concepts such as velocity profiling, acceleration ramping, multi-axis synchronization, and trajectory planning. A rigorous focus on functional safety introduces Category 0 to Category 2 emergency stop systems, safety PLCs, interlocks, and redundant braking mechanisms. Through systematic troubleshooting and real-time cue execution, learners develop the operational fluency necessary to program and monitor dynamic scenic elements. Practical exercises culminate in system commissionings that test emergency responses, load capacities, and positional repeatability, preparing technicians to safely implement scenic motion across complex production environments.

InstructorJacob Calhoun

Prerequisites

STG 101

Course outline

Lectures, virtual labs, and graded assignments — completed in your browser.

01Lesson 1: Introduction to Stage Automation Systems and Mechanical Principleslecture

02Lesson 2: Winch Mechanics, Drum Geometries, and Cable Fleet Angleslecture

03Lesson 3: Electric Motors, Gearboxes, and Variable Frequency Driveslecture

04Hands-on Lab: Winch Mechanical Setup, Fleet Angle Verification, and Motor Tuninglab

05Lesson 5: Sensors and Position Feedback: Encoders, Resolvers, and Limit Switcheslecture

06Lesson 6: Motion Profiling: Velocity, Acceleration, Deceleration, and Jerk Rateslecture

07Lesson 7: Motion Controller Interfaces, Network Communication, and Cue Logiclecture

08Hands-on Lab: Programming Multi-Axis Coordinated Moves and Velocity Profilinglab

09Lesson 9: Safety Standards, Risk Analysis, and Functional Safety Principleslecture

10Lesson 10: Emergency Stop Topologies, Safety Circuits, and Safe Torque Offlecture

11Hands-on Lab: Wiring Emergency Stop Loops, Implementing Interlocks, and Fault Testinglab

12Lesson 12: Hydraulic, Pneumatic, and Linear Actuator Control Systemslecture

13Lesson 13: Routine Maintenance, Pre-Show Inspection Protocols, and Diagnosticslecture

14Capstone Service Project: Automated Rigging System Inspection and Commissioningassignment

Syllabus

["Week 1: Lesson 1: Introduction to Stage Automation Systems and Mechanical Principles", "Week 2: Lesson 2: Winch Mechanics, Drum Geometries, and Cable Fleet Angles", "Week 3: Lesson 3: Electric Motors, Gearboxes, and Variable Frequency Drives", "Week 4: Hands-on Lab: Winch Mechanical Setup, Fleet Angle Verification, and Motor Tuning", "Week 5: Lesson 5: Sensors and Position Feedback: Encoders, Resolvers, and Limit Switches", "Week 6: Lesson 6: Motion Profiling: Velocity, Acceleration, Deceleration, and Jerk Rates", "Week 7: Lesson 7: Motion Controller Interfaces, Network Communication, and Cue Logic", "Week 8: Hands-on Lab: Programming Multi-Axis Coordinated Moves and Velocity Profiling", "Week 9: Lesson 9: Safety Standards, Risk Analysis, and Functional Safety Principles", "Week 10: Lesson 10: Emergency Stop Topologies, Safety Circuits, and Safe Torque Off", "Week 11: Hands-on Lab: Wiring Emergency Stop Loops, Implementing Interlocks, and Fault Testing", "Week 12: Lesson 12: Hydraulic, Pneumatic, and Linear Actuator Control Systems", "Week 13: Lesson 13: Routine Maintenance, Pre-Show Inspection Protocols, and Diagnostics", "Week 14: Capstone Service Project: Automated Rigging System Inspection and Commissioning"]