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`Daktronics, Inc.
`STAGE EXHIBIT 1017
`EXHIBIT 1017
`
`

`
`Theatre Engineering and Stage Machinery .
`©Toshiro Ogawa
`'
`
`First published April 2000 by Ohm-sha (Japan)
`A title in continuous publication within the
`EntertainmentTechnology Press Consultancy Series
`Series editorzjohn Offord
`
`First English publication April 200i
`Revised September 2008,january 20 I 0
`EntertainmentTechnology Press Ltd
`The Studio, High Green, Great Shelford, Cambridge CB22 SEG
`Internet: www.etnow.com
`
`ISBN 978 I 90403l 02 4
`
`All rights reserved. No part of this publication may be reproduced in any material form (including
`photocopying or storing in any medium by electronic means and whether or not transiently
`or incidentally to some other use of this publication) without the written permission of the
`copyright holder except in accordance with the provisions of the Copyright, Designs and Patents
`Act |988.Applications for the copyright holder's written permission to reproduce any part of
`this publication should be addressed to the publishers.
`
`The contents ofthis publication are provided in good faith and neitherTheAuthor norThe Publisher
`can be held responsible for any errors or omissions contained herein.Any person relying upon the
`information must independently satisfy himself or herself as to the safety or any other
`implications of acting upon such information and no liability shall be accepted either by The
`Author or The Publisher in the event of reliance upon such information nor for any damage
`or injury arising from any interpretation of its contents.This publication may not ‘be used in
`any process of risk assessment.
`TESM I 0l2l0i-I0
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`4.4.|0 Motorised Winch Fly
`
`I
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`
`Systems
`The temporaiy assistance ofa portable
`electric deck winch is sometimes used
`in the theatre practice to manipulate
`a standard manual counterweight
`fiy system or a sandbag/hemp line
`system.
`This type of winch is much the
`same as the capstan deck winches
`aboard cargo ships. A rope hooked
`to the bottom of the weight arbor (or
`to the clamp to which the sandbag is
`fastened) is stretched to the portable
`winch located on the fly gallery.
`The rope is then wound two or
`three times around the capstan of
`the winch, which keeps turning at a
`constant speed. By applying tension
`on the free end, the capstan pulls
`the rope by friction. The winch is
`normally installed on a caster frame
`with locking device to secure to the
`counterweight guide rail or to the
`gallery structure. An arrangement
`by which the winch is mounted on
`the guide rail is a convenient means
`for providing speedy, flexible, and
`safe operation. The portable closed-
`loop type winch drives are utilised
`with a counterweighted system. In
`the Broadway production of The
`Lion King built by Entlo (or Scenic
`Technologies), the counterweight
`assist winch system is installed in’
`the Shiki Group’s Spring Theatre in
`Tokyo.
`
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`Fig. 4-41 Load distribution by
`Peter Albrecht C0,
`
`drawing: Peter Albrecht
`
`Qllglii
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`SALLRE
`
`RIIEE.
`
`Fig. 4~42 Compensation wire rope
`(or chain)
`
`I58 Theatre Engineering 8: Stage Machinery
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`Fig.4—44 J.R. Clancy portable
`capstan winch, photo: J.R. Clancy
`
`
`
`Fig.4—43 Compensation’ chain and
`lower tension block
`
`
`
`
`
` a._Direct Drive (Dead Haul) Winch
`System
`Aside from a temporary deck winch
`to supplement the normal fly work; there are basically two types of
`motorised winch flying systems. In the simple winch system, the cables
`ound directly to a multi-grooved wire drum
`tied to the scenery batten are w
`powered by a motor. No counterweights
`are employed. This system is also used for
`frilled French decorative curtains, the light
`bridge, cyclorama battens and many new
`modern flying systems.
`The Metropolitan Opera House in New
`York is equipped with the Metromatic
`system developed by Peter Albrecht
`Company consisting of 109 battens
`independently powered by DC motor
`winches located on the grid. The 109
`winches are grouped into 30 control units,
`with six mastering units provided to operate
`the 30 control units. Each batten is capable
`of a 5kN load at adjustable speeds ranging
`from 0.005-1m/s within a position tolerance
`of £1.5mm. An advanced simple winch
`system comes with a centralised control
`4
`
`
`
`Fig.4—45 “Opera Winch” by
`Scenic Technology, USA to
`convert manual counterweight
`system to a portable winch,
`145 wide cable drum, built-in
`motor control/inverter
`
`Theatre Engineering & Stage Machinery I59
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`Fig. 4-4 7 Direct drum winch Drive
`
`Fig. 4-46 Big Tow Winch by Stage
`Technologies
`panel equipped with pilot indicators (CRT screen) and level setters, and
`operates either by means of an electronic servo motor, encoder or in an
`older system, mechanical wire traction and regulators for variable speed
`control. The flying system in the “Olivier” at the Royal National Theatre
`in London consists of 170 Sky Hooks, which are double purchase point
`suspension moveable in tracks installed under the grid, at a maximum
`speed of 2m/s, each capable of maximum load of 2kN. The accuracy of
`the resetting position is within :l:6mm.
`
`b. Counterweight Assisted Motor Winch
`To move the entire estimated load by a simple winch is a costly proposal,
`especially if variable speed is required for the electric motor. By counter-
`balancing the specified payload, the size of such winch system can be
`reasonably reduced, and thus made economically feasible to install. This is
`the advantage ofthe second motorised winch system, the counterweighted. -
`system.
`L
`T
`D
`T
`The principle of
`counterweight assisted
`motor driven systems is
`that of ordinary elevators.
`The load-bearing wire
`ropes from scenery battens
`are tracked in the grooves
`ofmotor powered traction
`drum, and then lowered
`.
`T
`£1
`a
`along a counterweight ,
`guide to be fastened to the Fig. 4-48 DC motor direct drum ‘dead haul’
`weight arbor. Generally, winch system, Metropolitan Opera House,
`one half of the payload New York
`
`I60 Theatre Engineering & Stage Machinery
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`is specified as the standard
`counterweight forwthe system
`Double purchase traction is
`often specified to accommodate
`specific conditions derived
`from the requirements of side
`stage opening. The required
`counterweight increases twice as
`much by double purchase.
`The more reliable counter-
`
`weight assisted system utilises
`‘closed loop drive’ where the wire
`rope is tied to the top and bottom
`ofweight arbor and wound on the
`winch drum.
`
`
`
`Fig. 4-49 Opera Garnier is direct drum
`winch by BBB C0. (total of80 battens,
`40cm pitch, load capacity 10kN, speed
`0.00] -1 .2m/s
`
`
`
`Fig. 4-50 Waagner Biro is winchfor thefuture “Direct Drum” with 360mm
`diameter drum for 6mm x 6 wire ropes, I2kW motorfor 10kN-1.2m/s or 6/cN~
`2m/sec performance with 45dB noise ratio
`
`Theatre Engineering & Stage'Machinery ‘I 6|
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`at the
`1 m/s
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`I62 Theatre Eng
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`ig. 4-52a "Synchro Disk” by
`:43 ratio
`Treverk B V (NederlanaD,/ 1
`planetary gear built—in 1100mm
`diameter — 395mm wide PBS
`
`cable drum for 8x5mm wire rope
`with German “LENG ” permanent
`magnet synchronous motoi; 2.2m/
`sec, 7. 5kN load capacity, "UNI-
`Drive” (by Control Technology),
`PLC and two set ofmagnet-type
`brakes are built in
`
`
`
`...(.¢..v..un.......
`
`ig.
`4-52b 128 set Synchro Disk at Shouwburg Harmonie, Leeuwarden,
`Holland Photo: Trekwerk
`
`Theatre Engineering & Stage Machinery I63
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`Sweden), photo: Mannesmann Rexroth
`
`
`
`
`Fig. 4-53 Modular direct drum winch (Gzbteborg Opera,
`
`Backclothwlnch
`
`edge of
`,.x machine
`/ - boom
`
`Fig. 4-54 Installation ofmodular direct drum
`winches in a sound damped machine room.
`Drawing: Mannesmann Rexroth
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`Fig. 4-55 Cozmterwe
`traction drive
`
`1' ht assisted
`
`Fig. 4-5 7 Japanese counterweight
`assisted traction drive at the Tokyo
`Bunka Kaikan by Morihei
`
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`ig. 4-58 Closed loop
`counterwe
`ight assistedfly system
`
`ig. 4-59 German tract
`photo: BTR
`
`ion drive,
`
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`Fig. 4—60 German closed loop
`counterweights assistedfly system,
`photo: BTR
`
`Fig. 4-61 Counterweight assistfriction
`drive manufactured by Waagner Biro,
`Hong Kong Culture Centre
`
`w
`
`‘
`
`'
`‘
`”
`’
`Fig.4—62 Counterweight assist
`hydraulicfriction drive manufactured
`by Kayaba Industries
`
`4.4.l0.l Hydraulic Motor Drive
`Hydraulic motors are used instead
`of high revolution electric motors
`to take advantage of the low speed
`(60rpm)/high torque characteristics
`of hydraulic power. There are also
`two types of drives: direct drum
`winch type and counterweight assist
`f ' t'
`l
`l
`'
`.
`“C lon/C osed Oop drwe
`4.5 Spotline (Point Hoist)
`When it is necessary to hang a single
`chandelier over the stage, it is best to use a single line from the grid, rather
`than the whole length ofa scenery batten. Standard scenery battens are also
`1
`inconvenient at times when many scenery pieces are rigged at diagonal
`angles in relation to the proscenium.
`,
`For example,‘a castle wall has to be rigged diagonally stage left. Battens
`' #1 and #10 are picked up and extension wire ropes dropped to secure the
`scenery piece. The extension cable on Batten #10 is tied several metres
`from the end of the batten, and the extension'cable on Batten #1 is tied
`to the end of the batten. The wall piece hung diagonally from Battens #1
`and #10 now blocks movement for Battens #2 to #9. These eight battens
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` Fig. 4-63b SynchroP0int by Trekwerk,
`
`
`
`Fig. 4—63a Portable electric spotline
`winch, Hong Kong Culture Centre
`(Waagner Biro)
`
`Payload 250Kg, 22m travel at
`I . 3m/sec
`
`
`
`cannot be brought down lower than thelcaistle wall, and become unusable
`for rigging work.
`The simplest spotline can be a hemp-line, if the load weight doesvnot
`exceed 0.2-‘0.3kN. Counterweights are very
`rarely used with spotlines, except on hemp
`lines with sandbag. However, the cables
`from a counterweight system are untied from
`the batten and used individually for special
`rigging by adding extra extension cables,
`and small sandbags or weights are added to
`the lines not being used for spotline rigging.
`The popular spotline system has a portable
`single line winch, which can be located on the
`
`
`
`Fig.4-66 Opera Garnier
`has stationary Spotline
`' Winch system made by
`Germany is BBB (The
`winches are placed in a
`sound darnped machine
`room on the upper griaD
`
`A
`
`
`
`Fig. 4-65 Stationary Hydraulic Spotline Winch,
`by Mannesmann Rexroth
`
`‘
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`Theatre Engineering 8: Stage Machinery I67
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`grid, and an operating line is lowered directly down to the stage. Other
`spotline systems utilise simple winches placed either directly on the grid,
`or vertically or horizontally on the grid sidewall. The line is stretched from
`the winch, and dropped down to the stage through either fixed or movable
`loft block. The position of the block defines
`the position of the spotline.
`In summary, the maximum load of a
`motorised spotline varies from 1 to 10kN.
`Spotlines are positioned by mounting movable
`loft blocks on the grid or upper grid structure
`to the position where the spotline is needed.
`The winch unit, however,
`is generally
`permanently located. For greater ease in
`spotline rigging work, an eyelet, carbine hook,
`or other device should be fastened to the end
`‘of the line, and, if possible each line should
`V
`-
`~
`'
`be equipped with upper and lower trimming
`limit switches and adjustable speed control. F1394-57 P0Siti0" Of
`Among the various spotline systems, "Spotlines “"9 Set by movable
`the Izenour Synchronous Winch
`‘Sheaves at 0103"” G“r"ie7
`System is one of the best known
`(Fig.4-68). Developed by Professor
`George Izenour of Yale University,
`USA, the system consisted of
`vertically placed drum, an idler,
`guide pulley on the vertical shaft,
`and a horizontally positioned DC
`motor. The cable from the winch
`wasldropped to the stage through
`a swivel-mounted loft block on the
`upper grid structure. The Ward-
`Leonard converter regulated the DC
`motor, and two sets of alternators
`(converters) are installed for the
`system, enabling ‘simultaneous F,-g_4_68r1Zen0u, Synchronous
`control of 6-8 lines each during Spot],-,7e,_g3,S,em at UCLA’ photo;
`raising 01‘ lowering. The m3Ximll1Tl Theatre Technology, George Izenour
`
`
`
`I
`;
`'
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`E
`T
`
`r
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`I68 Theatre Engineering 8: Stage Machinery
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`load for each Izenour winch was l.25kN and the motion tolerance was '
`
`2% (+30cm difference in 15m of travelling distance). Because of the
`small diameter of the wire drum of the winch, the maximum speed
`was a relatively slow 60cm per minute. It was also difficult to use
`with various delicate offset timings since the entire system had to be
`grouped in pairs. The Izenour Spotline System was originally installed in
`1963 in the McGowan Hall at UCLA, and renovated in 1986.
`Deutsche Opera Berlin was ‘equipped with six vertically placed
`synchronous winches located on the grid, each capable of a 3kN load. The
`Stationary Spotline systems had been in use for some time in Germany. The
`systems installed in the Frei Volks-biihne and the Bayreuth Festspielhaus
`were among the early models. At the Volksbiihne, a main shaft located
`along the fly tower wall, equipped with a total of 12 cable drums, each
`capable of a 5kN load, was driven by a two-speed motor. Cables were
`stretched from the drums via individual sheave to the stage, and the total
`maximum weight ofthe system was 30kN. At the Bayreuth Festspielhaus,
`the shaft was set parallel to the proscenium, and driven by a variable speed
`motor, yielding speed control at 0 — 0.75m/s, with a maximum speed of
`l.5m/s without load. A total of 18 cable drums were mounted on the main
`
`shaft, connected by means of magnetic clutches. Three drums were located
`every 4m, with a maximum 7.5kN load per line.
`A significant improvement over these systems are the so-called ‘3—4 fixed
`points-in—line’ and ‘4 - 5 fixed points-in-‘line’_ systems. An early model
`was installed in the Studio Theatre of the Frankfurt City Theatre complex
`(Studio der Stadtischen Biihnen Frankfurt). Instead of a conventional
`flying system with permanently fastened scenery battens, a group of lines
`consisting of three or four wires was placed parallel to the stage opening
`from downstage to upstage making a total of25, lines. From each spot on a
`line a cable was stretched to the cable drum locatedin the basement stage
`left, which was mounted on a master shaft driven by an electric motor. A
`group of manual clutch levers were located atstage left to engage each
`cable drum to the main shaft and any one ofthe stationary spotlines could
`be lowered or raised by operating the relevant clutch lever. It should be
`noted, however, that the simultaneous random lowering and raising of
`lines was notpossible because ofthe main shaft’s rotation in one direction.
`The manual clutch system is replaced with a magnetic clutch at the
`Ingolstadt City Theatre and was combined with a normal hand-operated
`
`Theatre Engineering 8; Stage Machinery I69
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`counterweight system. Along with 16 counterweighted battens placed
`450mm apart, there were 19 sets of 4-5 points-in-line stationary spotlines
`totaling 90 spots altogether, capable of a 0.75kN load each, at a variable
`speed of 0 — 80cm/s. The system could be operated simultaneously with
`25 spots fully loaded. This system presented the same problem, with
`simultaneous up and down movement impossible. However, the hand-
`operated battens provided the possibility of more flexible fly manipulation.
`It was also possible to perform complex shifts by manipulating remotely
`controlled magnetic clutches through grouping masters.
`The late Professor Thomas Miinter of the Berlin Technical University,
`the protégé of Professor Walther Unruh, used the 4-5 points-in-line sys-
`tems for his various theatre projects. It was a very convenient system for
`a theatre with economic limitations that desired the use of spotlines. The
`Ulm Municipal Theatre built in 1963, renovated in 1993, has a 4-5 point
`system with individualelectric motors and magnet-clutch coupled winch
`drums (load capacity 1kN)2“. See Fig.4-69,» 4-70 and 4-71.
`
`
`
`Fig. 4-69 Ulm City Theatre ’sfixed~
`point clutched winch battens,
`plan: BTR
`
`A
`
`_
`_‘
`‘
`mg-4'70, Ulm CW Thealm d"aW”7g-'
`BTR
`.
`
`
`
`
`
`2“ Worm and lgolstadt theatres had the same system
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`4.5.| Track Guided Spotline
`The Olivier Fly System at the Royal
`National Theatre, London consists
`of 170 Sky Hooks using a three-
`phase AC induction motor driven
`by a six-phase Cycloconvertor
`which provides a roughly sinusoidal
`three phase output at between
`zero frequency and 19Hz. The_
`motors are therefore only running
`at a maximum of about 500rpm,
`eliminating high frequency noises
`associated with the winding and
`bearings. The Cycloconvertor also
`providesfull motor output torque
`at standstill, which enables the
`winding drum to be driven directly
`by the motor without a gearbox.
`There are 36 Cycloconvertor drives,
`,
`V
`-
`,
`including one spare unit, controlling
`F,'g_4_71 U1,” C,-ty Theatre,
`any one of the 170 hoist units via
`a computer. Each drive unit is ph0to.'BTR
`
`ROPE UEFLECIM
`
` _l
`
`SCENERY Hams
`
`UVERLOAD l SLACK L
`
`Fig. 4-72 Tracked Spotline system
`Olivier Theatre (National Theatre,
`London), drawing: Richard Brett
`
`Fig. 4-73 Tracked Spotline, by BBB
`(six points per line possible),
`photo: BBB
`
`’
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`provided with six programmable
`dead positions. There are six
`operational controllers (No.1 - 6)
`and zero controllers on the main
`
`control panel. The zero controllers
`function as the main controller,
`and include a numeric keyboard to
`select hoists, group numbers or cue
`““mb°’S'
`
`
`
`Fig. 4-74 Vertilift, photo: GALA
`
`’
`-
`-
`4.6 Vertilift
`Self—c1imbing battens are popular in television studios. For Vertilift, a
`shaft of required length is installed horizontally on the grid and each
`suspension line is wound to the drum mounted on the shaft. The wire
`drums are designed toikeep constant suspension points by self-adjusting
`extendable drive shaft. The drums rotate on a pair of idlers, which run in
`the wire grooves maintaining constant suspension points. The standard
`system is rated to 1 1kN with a lifting speed up to 0.9m/s either by electric or
`hydraulic motor (Fig.4-74, 4-75). There is an application ofVe1tilifi, which
`has manual hand-lines similar to regular counterweight fly system.iThe
`
` YRAVELLIHG DRUM FDR
`
`D DEBNEC FLEEY ANGLE
`
`
`
`SUPPWYIIB SYRUCYURE
`S(Pl"l]R|’ VIIEELS
`5 U2‘ DIMITER VIIRCADCD DRUM
`CLCCYQIC HUIDR AND IRAKE
`SECONDARY SAFEYY SPRAG BRAKE
`ELECIRXCAL JUNCYIEII BDX
`‘
`
`-
`-'
`
`Ill! IEIALNER
`
`PKJSIHKN EGNYRU. LIMIT -SVITCH SPLICE
`
`
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`
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`
`A
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`Fig.4—75 Vertilift (electric motor
`version), drawing: GALA