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ISAC Stage Automation Capstone (Ohio Northern University)

The xxxx Center for the Performing Arts at xxxx University has limited options for moving large scenery. The current process requires production staff to manually move scenery across the stage and this movement can cause injury to the stagehands or performers on or around the scenery. This paper presents the design and development of an electromechanical system to move scenery across stage using a winch, drive system, and controller, which will provide consistent, repeatable, and reliable movement. The implementation of this system allows for the relocation of stagehands and an improved viewing experience. This system saves money for the Center in comparison to renting this equipment.

The designed system contains a 3 hp, 230 VAC, 3 phase induction motor incorporating a 10:1 speed reduction system connected in series and contained within a metal frame. The output of the speed reducer drives a grooved drum on which the cable is wound. The cable exits the frame and is attached to the scenery. The controller and human machine interface for the system is a combination of a Programmable Logic Controller (PLC), computer, and Variable Frequency Drive (VFD) system. This integrated subsystems receive user inputs and drive the mechanical system as desired by the show director. The system contains a stopping function contained in the VFD in conjunction with the motor and an external brake. The external brake is part of the emergency braking system, triggered by the user.

The deliverables to be provided to the client consist of a winch, drive system, controller, a user manual and maintenance manual for the whole system. All components within this system will be readily available for repair or replacement.

The paper is organized in sections that cover the elements of the paper as follows: problem statement and literature survey, design realistic constraints and industry safety standards, alternative solutions, design evaluation metrics, the selected solution, design concept, components and materials, implementation and prototyping, project budget, project schedule, and conclusion.