J.R. Clancy Provides Design, Manufacture and Installation of Theatrical Equipment Worldwide                                      1-800-836-1885
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
                         
 
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  Automated Rigging Backstage Tour  
 
 
 
           
     
   
         
Automated Rigging Backstage Tour
           
           
How Automated Rigging Works
Yesterday's simple wood-frame and painted fabric flats have been replaced by heavy, multiple-element sets that must be flown with speed and accuracy in complex sequences. The muscle of automated rigging and the precision and repeatability granted by computer-based electronic controls have made it possible.  
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Line Shaft Winch
A line shaft winch uses a separate drum for each lift line. Since the lift line goes directly to the load, there is no need for head or loft blocks and the wall or floor space they require. This makes line shaft winches ideal for renovations in which there isn't much space nor enough steel framework to handle side loading.  
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Universal Joints & Shafts
Universal joints connect each line shaft to its drive motor and the drums. Regardless of how solid a structure seems, it will move. Snow loads in temperate climates distort the roof structure, while aboard cruise ships, the entire structure flexes with each wave. Without U-joints to compensate, bearings can fall and shafts may bind or seize.  
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Point Hoists
When great flexibility is required, a gang of spot lines or point hoists work as a team to lift or lower difficult loads. Smaller, portable point hoists can be fixed to the grid, or larger fixed units can team up with movable spot blocks. Regardless, point hoists working in concert must be synchronized with electronic controls to keep the scenery in position. The control software should be able to monitor the position of each spot line hundreds of times each second to keep all lift lines taut.  
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Mule Block
This sheave redirects a lift line from the point hoist to a loft block allowing a lift line to be put anywhere over the gridiron.  
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Batten Clamp
Batten clamps grip the pipe batten along its length, usually on 10-foot centers. They should be load rated for safety.  
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Head Block
The multi-sheave head block spaces sheaves so cables drop directly on to the correct portion of the winch drum.  
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Loft Block
Mounted overhead or at grid level, the loft block is a simple pulley that turns the lift lines 90° toward the stage. Sealed precision ball bearings allow the sheave to turn smoothly and quietly on the shaft. Grooves in the sheaves should be machined or molded precisely so they support the line through at least 150° of its circumference.  
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Gear Motor
The combined gearbox, motor and brake provide speed reduction and power in the smallest space.  
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Drum Winches
Drum winches, with their integral motor gearbox and brake can be mounted on the floor, in the gallery or on the grid. The winch drums are helically grooved to keep the wire rope wound in a single layer so as not to change the drum diameter and alter the lift rate. The drums are long enough to accommodate all the lift lines for a particular set.  
Back to Drawing
   
Electronic Controls
Proprietary software and the computers that run it allow set changes to be as carefully choreographed as on-stage movement. The newest generation of electronic controls allows a script to be written for each individual production calling for rapid and very precise movements of scenery elements in complex sequences. The controls offer repeatability, performance after performance, but still allow human overrides to keep pace with the speed and rhythm of individual performances. At the same time, the software also makes sure each command is within the machinery's performance limits. Electronic controls that vary the speed of motors include inverters and vector drives. Automated rigging is becoming more common as scripts call for the creation of special effects or moods in which scenery elements are moved at different rates in full view of the audience.  
Back to Drawing  
   
Lift Lines
The wire rope lift lines that support the pipe batten are the tendons that hold the rigging system together. Galvanized steel aircraft cable is preferred for its strength and flexibility.  
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Cable Drum  
Cable drums are properly spaced so they drop lift lines from the grid and support the pipe batten.
 
 
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Pipe Batten  
Hundreds of pounds of lighting fixtures, scenery, sound equipment - anything - may be hung from the pipe batten so it had better be robust and rigid. Usually made in 20-foot lengths, ours have 18-inch iron splices that slip into the pipe to stiffen and strengthen the joints.  

 
 
 
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"Line Shaft Winch" - A line shaft winch uses a separate drum for each lift line. Since the lift line goes directly to the load, there is no need for head or loft blocks and the wall or floor space they require. This makes line shaft winches ideal for rennovations in which there isn't much space nor enough steel framework to handle side loading. "Universal Joints and Shafts" - Universal joints connect each line shaft to its drive motor and the drums. Regardless of how solid a structure seems, it will move. Snow loads in temperate climates distort the roof structure, while aboard cruise ships, the entire structure flexes with each wave. Without U-joints to compensate, bearings can fall and shafts may bind and seize. "Point Hoists" - When great flexibility is required, a gang of spot lines or point hoists work as a team to lift or lower difficult loads. Smaller, portable point hoists can be fixed to the grid, or larger fixed units can team up with movable spot blocks. Regardless, point hoists working in concert must be synchronized with electronic controls to keep scenery in position. The control software should be able to monitor the position of each spot line hundreds of times each second to keep all lift lines taught. "Mule Block" - This sheave redirects a lift line from the point hoist to a loft block allowing a lift line to be put anywhere over the gridiron. "Batten Clamp" - Batten clamps grip the pipe batten along its length, usually on 10-foot centers. They should be load rated for safety. "Head Block" - The multi-sheave head block spaces sheaves so cables drop directly on to the correct portion of the winch drum. "Loft Block" - A pulley mointed to the gridiron or support steel that supports and changes the direction of a lift line cable between the load and the head block. "Gear Motor" - The combined gearbox, motor and brake provide speed reduction and power in the smallest space. "Drum Winches" - Drum winches, with their integral motor gearbox and brake can be mounted on the floor, in the gallery or on the grid. The winch drums are helically grooved to keep the wire rope wound in a single layer so as not to change the drum diameter and alter the lift rate. The drums are long enough to accommodate all the lift lines for a particular set. "Electronic Controls" - Propietary software and the computers that run it allow set changes to be as carefully choreographed as on-stage movement. The newest generation of electronic controls allows a script to be written for each individual production calling for rapid and very precise movements of scenery elements in complex sequences. The controls offer repeatability, performance after performance, but still allow human overrides to keep pace with the speed and rhythm of individual performances. At the same time, the software also makes sure each command is within the machinery's performance limits. Electronic controls that vary the speed of motors include inverters and vector drives. Motorized rigging is becoming more common as scripts call for the creation of special effects or moods in which scenery elements are moved at different rates in full view of the audience. "Lift Lines" - The wire rope lift lines that support the pipe batten are the tendons that hold the rigging system together. Galvanized steel aircraft cable is preferred for its strength and flexibility. "Cable Drum" - Cable drums are properly spaced so they drop lift lines from the grid and support the pipe batten. "Pipe Batten" - Hundreds of pounds of lighting fixtures, scenery, sound equipment - anthything - may be hung from the pipe batten so it had better be robust and rigid. Usually made in 20-foot lengths, ours have 18-inch iron splices that slip into the pipe to stiffen and strengthen the joints.