Custom Multi-Axis Synchronized Stage Automation for National TV Music Finals

Background: For the finals of a national primetime singing competition, Our team delivered a high-precision kinetic scenography system capable of turning a complex visual concept—vertical harp- and pipe-organ-inspired waves—into precise, repeatable, music-driven motion across rehearsals and live broadcasts.

This is a fully customized 120-axis CNC lifting-column array that served as a dynamic scenography element — a motion-capable stage structure that rises, rotates and responds to the show’s rhythm — while also functioning as a synchronized LED surface for integrated visual-motion effects.

Key Challenges

►Multi-axis Motion Control: Hundreds of lifting columns moving in multi-layered wave patterns synchronized to music.

►Touring consistency: Identical cues across venues with different stage dimensions.

►Broadcast-grade reliability: Safety interlocks, collision avoidance, and stable positioning under dynamic loads.

►Fast deployment: Limited load-in and technical rehearsal time.

Our Solution — Black Warrior Stage Automation System

YZDITEC supplied a turnkey motion-control system built around our proprietary Intelligent Console For Stage Automation:

►Deterministic EtherCAT real-time control: 120 synchronized axes with ±1 mm repeatability.

►Modular motion nodes: Distributed controllers and drive units for scalable setup and simplified cabling.

►Digital-twin verification: 3D simulation for cue design, kinematic validation, and collision-free pre-runs.

►Integrated safety stack: Real-time monitoring, hardware interlocks, and automatic collision detection.

►Operator-focused HMI: Cue programming, live overrides, diagnostics, and a standardized cue library for quick venue adaptation.

Implementation & Acceptance

►Digital-twin commissioning minimized on-site setup time.

►Full live on-site acceptance completed with 120-axis synchronized wave cues.

►Safety, repeatability, and real-time system response validated under broadcast conditions.

Outcomes & Benefits

►Creative consistency: Precise reproduction of complex wave choreography across all shows.

►Reduced setup time: Modular architecture + digital twin = faster load-in and debugging.

►Operational safety: Continuous monitoring and automated collision-avoidance for on-air reliability.

►Scalability: Easily expandable and adaptable to different stage sizes and future touring requirements.

Technical Snapshot

• 120 synchronized axes • EtherCAT deterministic network • ±1 mm repeatability • Digital-twin validation • Real-time safety monitoring • Modular motion architecture

💬Looking for a custom kinetic stage system? Let’s talk.