Flyhouse and ELPLANT implemented an innovative automated theater concept with more than 60 configurations on the World Trade Center campus
At the foot of Manhattan’s One World Trade Center building and across a pedestrian path from the 9/11 Memorial & Museum’s twin reflecting pools stands the Perelman Performing Arts Center (PAC NYC). While it offers programming similar to other major New York City theaters, the mission of this configurable gathering space is distinctly communal.
“PAC NYC is a place of civic healing,” says Miranda Palumbo, Director of Digital Content at PAC NYC. “Because we are on the World Trade Center campus, it's our responsibility to help everyone celebrate life.”
To provide “a stage for every story,” PAC NYC features three performance spaces that can flexibly combine or divide into over 60 configurations. The theaters also support dynamic set changes and flying performers through the air with advanced overhead hoists.
“We could produce three different pieces of work at the same time or just one,” Palumbo explains.
This required functionality presented core technological challenges. To harness the necessary backstage engineering behind the performance art, PAC NYC directed The Chicago Flyhouse, Inc. and its programming partner, ELPLANT, to implement a safe, reliable, and flexible stage automation system.
“We’ve always enjoyed challenging projects,” says Mark Witteveen, Founder and Senior Project Manager at Flyhouse. “They keep our people engaged and push our technology forward.”
To provide the necessary configurability, Flyhouse relied on PC-based control and EtherCAT solutions from Beckhoff – with a vast amount of I/Os and PC-based controllers working in concert. These technologies ensured seamless operation and high adaptability, making every performance possible.
Entertainment engineering experts respond to the casting call
“The Perelman was a unique and exciting project,” Witteveen says. “You rarely build new theaters in New York City, especially in Manhattan’s Financial District. Plus, the design team and consultants wanted to develop a flexible space.”
At PAC NYC, Flyhouse used its distributed “MoM-and-Kid” control concept. A central server (the MoM, short for Master of Machines) with an HMI screen communicates to distributed modules (the Kids). The more than 30 Kid modules at PAC NYC each have their own Beckhoff embedded PC and EtherCAT I/O wired to drive Flyhouse’s ZipLift hoists and other equipment. The modules can be easily moved, connected to other hoists, or swapped for maintenance.
Still, the large number of Kid modules and their associated motion axes throughout the theater level raised the bar on the facility’s networking capabilities. The Flyhouse technologies also needed to interface with other vendors’ solutions, for example, the systems to raise and lower the massive walls or change the floor configuration to be flat or stairstep up. So, safety zones had to adjust dynamically as spaces changed to ensure human and equipment safety.
“Every time the theater configuration changes, so do the control and safety requirements,” Witteveen says. “We've made decisions to maximize the safety of our crew in the hundreds of possible scenarios we’ve run, but in the end, they're going to find more, and we can add them.”
Prior to the PAC NYC project, Witteveen already had a deep understanding of the theater industry. Back in sixth grade, a friend convinced him to help with a production of “The Wizard of Oz.” His role consisted of flipping breakers to turn lights on and off. From these small beginnings, he majored in theater technology in college and later established Flyhouse.
“The challenges are interesting, and the pressure is high,” Witteveen says. “When you have 100 or 1,000 people coming to see a show, it must be ready without delay. So, the idea that something isn't finalized – or isn’t safe enough – simply isn’t an option.”
Flyhouse provides innovative rigging design, fabrication, and installation. Venues ranging from hospitals and high schools to theaters and arenas across the world seek out these specialists for rigging, hoisting, and performer flying equipment. The Chicago-based team has built its reputation on the fact that it fully understands the technology and the stakes for these kinds of projects.
“You can lose 10 years of reputation with one component that's acting erratically, so it’s vital to partner with the right companies,” Witteveen says. “Even though the duty cycles are relatively short in theaters, we need the reliability that comes with industrial automation.”
Here, Beckhoff supplied an ideal solution. “We offer many technologies designed for the machine control world that can be instantly applied to the entertainment industry,” says Jason Toon, Entertainment Industry Specialist at Beckhoff USA. “By acting on industry developments and customer feedback, we’ve also developed custom software packages and compact hardware targeted specifically to entertainment engineering.”
Flexible automation technology takes center stage
Flyhouse collaborated with Beckhoff USA and ELPLANT to design next-generation control modules. ELPLANT, an ISO 9001-certified systems integrator based in Serbia, brought expertise in industrial automation and entertainment applications.
“For this project, Beckhoff was undoubtedly the logical choice, as few systems could provide such a modular and configurable architecture,” says Aleksandar Arsić, CEO of ELPLANT.
TwinCAT software offers an end-to-end engineering and runtime platform that incorporates all automation and control functionality. Integrated into Microsoft Visual Studio®, TwinCAT empowers engineers to program in the most apt language for the application or their skillset.
“For this system, we used TwinCAT PLC, NC PTP motion control, TwinSAFE safety systems, extensive EtherCAT communication, TwinCAT PLC visualizations, TwinCAT HMI, database communication, and ADS with third-party applications, such as C# WPF (Windows Presentation Foundation) operator consoles and similar solutions,” Arsić says.
Another key enabler of the modular design was the EtherCAT industrial Ethernet System, explains Arsić: “This real-time communication allowed us to configure the topology so that each CX9020 Embedded PC or other EtherCAT device operated as an independent sync unit.” Much of the equipment also features EtherCAT P, which combines data and power on one cable.
This configuration allows techs to remove or add kid modules without taking all the others offline. Beyond sheer speed and robust diagnostics, the EtherCAT supports free selection of topology. It also offers hot connect functionality and automatic addressing of devices for plug-and-play installation.
“In terms of performance, one axis controlled by a Beckhoff IPC could seamlessly follow another axis controlled by a different Beckhoff IPC via real-time EtherCAT communication,” Arsić says.
Flyhouse also harnessed TwinSAFE integrated functional safety solutions. The “black channel” communication via Safety over EtherCAT (FSoE) transmits safety information over the standard EtherCAT network, rather than a separate, hardwired system. Beyond the reduction in wiring effort and cost, TwinSAFE simplified implementation of the configurable theater concept.
Flyhouse deployed its Ease® Control Console in each theater space, simplifying axis operation with joysticks and a multi-touch screen built with TwinCAT HMI. The consoles can’t access axes outside the operator’s line of sight for safety reasons, according to Witteveen. So, when raising walls to combine spaces, the Ease consoles now need to control all the axes in that larger room. Likewise, E-stop buttons need to halt all motion in combined spaces if required, meaning that the mom-and-kid architecture must change on the fly.
“This seemingly simple idea proved incredibly complex to implement,” Witteveen says. “But with the flexibility of EtherCAT and software capabilities in TwinCAT, we pulled it off seamlessly.”
Magical PAC NYC experience earns a standing ovation
Every aspect of PAC NYC was intentional. The building’s foundation was acoustically isolated to ensure subway trains and other underground activity wouldn’t affect performances. The unique outer walls are made of thinly sliced slabs of marble and glass, letting sunlight in during the day and making the theater glow as a New York City beacon in the evening. The lobby level features a restaurant run by acclaimed celebrity chef Marcus Samuelsson and a stage where musical acts and other artists give free performances most days of the week.
The stage automation needed to be equally intentional. “These spaces wouldn’t work as well as they do without the technology from Flyhouse in collaboration with all of our other vendors,” Palumbo says. “By figuring out a magical language of art and engineering, the possibilities seem endless.”
For ELPLANT, the ability to develop large and complex systems remotely highlights the Beckhoff solution’s capabilities – not to mention development time and cost savings. “Beckhoff is the only system that allows us to execute over 90% of projects in simulation conditions without requiring any hardware,” Arsić explains.
“Over the last four years, we have worked with Flyhouse on demanding control projects for numerous performing arts theaters,” Arsić adds. “Every time, we’ve completed the work remotely from our office in Serbia. The Flyhouse team handled some projects entirely using our straightforward configuration tools. The Beckhoff system’s level of capability and flexibility is unmatched.”
PC-based control from Beckhoff readily supports ELPLANT’s advanced manufacturing execution system, MESWARM, which supports predictive maintenance, performance monitoring, and other Industry 4.0 initiative for companies across industries. MESWARM has provided advantages for Flyhouse in other theaters, and following a blockbuster pilot at PAC NYC, it will be added to that system during a future update.
In fact, the modular system will continue to support upgrades, and with a scalable, future-proof automation platform, this process won’t require a rip-and-replace of infrastructure. Instead, technicians can simply make changes in software or replace a device with a newer version.
Beyond reducing costs, this approach avoids unwanted intermissions to find obsolete components. To Witteveen, ensuring that the show will go on remains the most important goal.
“When the lights dim and the stage comes to life, the audience isn’t thinking about automation,” he says. “They’re simply immersed in the magic. That experience makes all the effort worthwhile.”
Ready to put the spotlight on your entertainment engineering and stage automation applications? Contact your local Beckhoff sales engineer today.
James Figy is the Marketing Content Leader at Beckhoff Automation LLC