Automated Motion Control System for a Studio Tour

We were commissioned to develop a custom automated pole arm motion system for use within a large-scale event space. The project combined precision motion control, advanced safety integration, real-time networking, and custom automation software to create a smooth, cinematic movement system capable of operating safely around performers and crew.

Originally, the brief appeared relatively straightforward: move a suspended pole between programmed positions. However, as the project evolved, the motion requirements became significantly more ambitious, requiring highly organic movement patterns and synchronisation with pre-rendered video playback.

Custom Motion System Design

The production team supplied the required movement speeds, loading information, and range of motion, allowing us to specify suitable motors, actuators, and control hardware for the application.

For this project, we incorporated a new range of actuators that we had not previously used, providing an opportunity to explore different motion characteristics and control techniques. The entire system was designed and programmed within the Beckhoff TwinCAT 3 environment, giving us precise real-time control over multiple motion axes simultaneously.

Creating Natural “Floating” Movement

One of the key creative requirements was for the arm system to move with a smooth, almost weightless floating effect rather than simple linear point-to-point motion.

To achieve this, we developed a custom mathematical motion profile using multiple sine-wave calculations. Three independent sine waves were combined to control the actuators and rotational movement simultaneously, creating a much more natural and fluid motion path.

This approach allowed the arm to move with a far softer and more cinematic feel than traditional automation systems, closely matching the visual style required for the production.

Integrated Safety Systems

Because the system operated close to performers and within a live production environment, safety integration was a major part of the project.

We designed and built a dedicated control cabinet incorporating:

• Emergency stop systems

• Start/stop controls

• Safety monitoring

• Automated shutdown functionality

  
  

We used the Beckhoff TwinSAFE ecosystem, replacing previous standalone safety hardware and allowing tighter integration with the overall control architecture.

Time-of-Flight Safety Scanning

To protect anyone working near the moving arm, we implemented a SICK safety laser scanner system.

Using programmable safety zones, we mapped out the physical area through which the arm could move. If a person entered this protected zone while the system was active, the scanner would immediately trigger a safety stop and shut down motion across the entire installation.

This aspect of the project proved particularly challenging due to the extremely tight installation tolerances. The scanning area had only a very small operating clearance between the moving arm and the scenic stage surface, which became even more complex after the set design changed height during installation.

Extensive calibration and on-site adjustment were required to ensure reliable operation while maintaining the required safety coverage.

Synchronisation with Video Playback

Partway through installation, the project specification changed significantly when the production team requested that the arm movement synchronise precisely with looping video playback.

This introduced an entirely new layer of complexity, requiring us to manually analyse the timing of the video content and match movement cues frame-by-frame in real time.

Although this was not part of the original design brief, the team successfully adapted the system during installation, fine-tuning the movement profiles to create smooth, natural motion that aligned convincingly with the projected visuals.

The experience also influenced how we approach future motion-control projects, particularly regarding playback recording systems and previsualisation workflows.

Network-Based Control Integration

The final system was integrated into the wider production infrastructure using UDP network communication.

External show-control systems could send simple commands such as:

• Run Sequence

• Stop

• Reset

The automation controller then returned confirmation packets to provide status feedback and ensure reliable communication between systems.

This streamlined approach allowed the entire installation to be operated remotely from the production’s central control environment without requiring additional standalone interfaces.

Combining Engineering & Creative Motion Control

This project brought together multiple engineering disciplines including:

• Motion control

• Real-time automation

• Safety systems

• Mathematical movement modelling

• Network communications

• Mechanical integration

• Live production technology

  
  

The final installation delivered a highly polished automated motion system capable of producing smooth cinematic movement while operating safely and reliably within a demanding live production environment.