Revolutionizing Stage Automation: Enhanced Flexibility with Reduced Complexity

The automation of modern theater stages demands the highest standards of precision, safety, and flexibility. Every stage is unique, and every production brings new technical challenges. This case study demonstrates how ootb automation GmbH developed a revolutionary system for a renowned theater operator that drastically reduces complexity while maximizing flexibility.

The Challenge: Custom Solutions as Cost Drivers

Theater stages are among the most demanding environments for automation technology. The technical equipment must meet the highest safety standards while not restricting the creative freedom of directors. Our client, an established provider of stage automation solutions, faced a fundamental problem: every new installation required extensive custom programming.

The consequences were severe: long planning phases delayed projects, development costs rose continuously, and error susceptibility increased with each new development. Each stage had its own peculiarities – different numbers and types of line sets, turntables, lift platforms, and traps. The previous solution consisted of developing software from scratch for each project or laboriously adapting existing code.

The client recognized that this approach was not sustainable in the long term. The vision was clear: a system had to be created that enables flexible configuration without requiring custom software development for each installation. Theater technicians should be empowered to configure and adapt systems independently – without depending on external programmers.

The Solution Approach: Thinking in Reusable Building Blocks

ootb automation analyzed the problem and developed a fundamentally new approach. Instead of writing individual code for each stage, a universal software platform should be created based on the concept of reusable components. The core idea: all typical stage elements – whether line sets, motors, frequency converters, or safety devices – should be available as preconfigured software modules that can be flexibly combined.

This vision required fundamental rethinking of software architecture. The system had to be able to create virtual representations of physical components, intelligently connect them, and automatically consider all safety-relevant dependencies.

The Implementation: RIO – Reusable IO Framework

After two years of intensive development, the time had come: RIO (Reusable IO Framework) went into operation. This innovative platform enables the creation of virtual control cabinet components that communicate with each other via standardized bus systems. Each component has its own configuration interface, allowing parameters to be adjusted without programming.

The Centerpiece: Intelligent Component Library RIO features an extensive library of predefined components. A hoist chain, for example, is available as a complete software object that already includes all typical functions: position control, limit monitoring, load monitoring, synchronization with other hoists, and emergency behavior. Users select the required components and connect them via drag-and-drop.

Flexible Axis Configuration A particular advantage of RIO is the autonomous control of individual axes. Each mechanical axis – whether a curtain track, turntable, or lift platform – can be configured and controlled independently. At the same time, the system allows complex synchronizations: multiple hoists can be grouped together, movement sequences can be choreographed, and safety interlocks are automatically considered.

Practice Meets Theory RIO’s true strength is revealed in everyday project work. What previously required weeks of programming can now be configured in days. A new line set? Simply select the corresponding component from the library, assign the I/O channels, enter parameters such as speed and acceleration – done. The system automatically generates all control logic including visualization and diagnostic functions.

Measurable Success: Time and Cost Savings

The introduction of RIO led to a dramatic improvement in project efficiency. Programming and commissioning times were reduced by an average of 60 percent. Errors arising from individual programming are largely a thing of the past, as the reused components have already proven themselves in numerous installations.

The flexibility gained during project execution is particularly valuable. Changes that previously required extensive recoding can now be realized by adjusting the configuration. This is of immense importance in theater practice, where requirements frequently change during the installation phase.

Reusability also extends to functional enhancements. New features developed for one project are automatically available as components for all future projects. This creates a continuously growing toolkit that becomes more powerful with each project.

Client Testimonial from Practice

Tiroler Festspiele, a long-time user of the technology, confirms its practicality:

“We have set up many productions with the Stage Automation system and value both its reliability and customer support. The ability to make adjustments ourselves without having to wait for external programmers every time has significantly improved our workflows.”

Tim Herold, Technical Director, Tiroler Festspiele

Technological Expertise at ootb automation

This case study exemplifies the core competency of ootb automation GmbH: the development of intelligent automation platforms that master complexity without transferring it to the user. Our range of services includes complete PLC software development, design of reusable automation platforms, and comprehensive consulting in optimizing automation processes.

The RIO framework represents our approach: through intelligent abstraction and modularization, we create systems that are both powerful and manageable. Theater operators can focus on what matters – the artistic production – while the technology works reliably and flexibly in the background.

If you also face the challenge of making complex automation systems more efficient, contact us. We analyze your specific situation and develop customized solutions that sustainably optimize your processes.