The Perelman Performing Arts Center in New York (PAC NYC) offers visitors a truly unique theater experience. Advanced stage technology makes its three performance spaces extremely versatile. At the foot of Manhattan’s One World Trade Center building and across from the 9/11 Memorial & Museum stands the PAC NYC. While it offers programming similar to other major New York City theaters, the mission of this 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.”

The venue features three performance spaces that can flexibly combine or divide into over 62 configurations. The backstage technology also supports dynamic set changes and flying performers through the air. To harness the necessary 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. Flyhouse provides rigging, hoisting, and performer flying equipment for venues across the world ranging from hospitals and high schools to theaters and arenas.

Distributed Control

Flyhouse incorporated its distributed “MoM-and-Kid” control concept where a central server, Master of Machines,(MoM), communicates to distributed modules (the Kids). The more than 30 Kid modules at PAC NYC each have their own Beckhoff CX9020 Embedded PC and EtherCAT I/O wired to control Flyhouse’s ZipLift hoists and other equipment. The modules can be easily moved, connected to other hoists, or swapped for maintenance.

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 such as the systems to raise and lower the massive walls or change the floor configuration to be flat or stairstep up. This meant that safety zones had to adjust dynamically as spaces changed to ensure human and equipment safety.

Beckhoff supplied an ideal solution. The EtherCAT and PC-based control technology provides a foundation for seamless operation and high adaptability. 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. CEO of ELPLANT, Aleksandar Arsić , explained, “Beckhoff was undoubtedly the logical choice, as few systems could provide such a modular and configurable architecture.”

The system incorporated 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.

Real-time communication allowed the team to configure the topology so that each 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, simplifying component exchange and plug-and-play installation.

Flyhouse also harnessed integrated functional safety with TwinSAFE terminals. Here, safety information is transmitted via Safety over EtherCAT (FSoE) 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 with a visualization built with TwinCAT Human-Machine Interfaces (HMIs). The consoles can’t access axes outside the operator’s line of sight for safety reasons, so, when raising walls to combine spaces, the consoles 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 could have been incredibly complex to implement, but with the flexibility of EtherCAT and software capabilities in TwinCAT, it was seamlessly implemented.

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 Mark Witteveen, 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. And that experience makes all the effort worthwhile.”

For more information: 

Beckhoff 

PAC NYC 

Flyhouse

Elplant