“Talk Show & Friends” — YZDITEC Stage Machinery Case Study

Project name: Talk Show & Friends

Client / Production: Tencent Video talk-show competition (Guests included Li Yuchun (singer), Chen Luyu (TV host), Da Zhangwei (singer), Luo Yonghao (entrepreneur and tech influencer), and Zhang Shaogang (TV host); 59 contestant groups on-site).

Scope delivered by YZDITEC: Full electromechanical design, manufacture and synchronized on-site control of the central stage mechanism (installed above center stage, also serving as support for lighting fixtures and LED background).

1. Background & Key Challenges

The creative brief required a mechanized, high-impact opening sequence driven by a large central ring. Technical and operational challenges included:

Achieving large angular displacements through synchronized multi-point actuation of an oversized central ring, while balancing expressive motion with smooth, stable operation.

Executing complex trajectories (arcs, spirals and multi-dimensional compound paths) with millimetre-level synchronization and seamless motion continuity across multiple actuators.

Satisfying live broadcast-grade requirements for redundancy, repeatability and high reliability during simultaneous live and streamed transmission.

Ensuring deterministic timing between mechanical motion and stage visuals (LED, lighting) for frame-accurate integration.

2. Our Solution — Executive Summary

YZDITEC delivered an end-to-end electromechanical and control package to meet these demands:

Hoisting system: Deployed 37 × C1-series intelligent CNC chain hoists with servo drives operating as a synchronized cluster. Each hoist uses servo motors with absolute encoders to retain position after power loss and to provide high-integrity feedback.

Real-time load balancing: Implemented closed-loop force equalization using motor feedback (torque/force) and internal hoist load measurements for continuous micro-adjustment, minimizing local overload risk.

Control platform: Coordinated multi-hoist scheduling and trajectory planning under YZDITEC’s proprietary "Black Warrior" intelligent control console, enabling continuous, smooth execution of complex trajectories; built on the EtherCAT real-time fieldbus for high-frequency synchronization and real-time status monitoring.

Validation & commissioning: Completed comprehensive factory performance and safety validation (including dynamic load and interruption response tests), followed by detailed on-site commissioning and acceptance. 

 Standards & certification: TÜV Rheinland, BGV-C1, CE; compliant with EN 17206.

 Result: Smooth, visually compelling mechanical motion under complex trajectories and large-angle swinging motion, with millimetre-level synchronization and real-time load-balanced operation that balances aesthetic impact and operational safety.

Talk show on-site commissioning and acceptance

Factory performance and safety validation

3. Key Technical Highlights (for industry clients)

Clustered synchronized architecture: 37 hoists act as a single coordinated system under “Black Warrior” control console, enabling multi-point linkage and unified trajectory following. Platform capacity: up to 128 control loops (axes) and management of 256 device models per master controller.

Model-driven real-time control: “Black Warrior” control console maps logical models to physical devices (models store runtime parameters). During execution the model mirrors rigging state for online monitoring, collision detection and over-limit warnings.

High-precision spatiotemporal control: Position command resolution 1 mm; programming time resolution 0.1 s; EtherCAT communication cycle 2 ms — ensuring broadcast-grade synchronization and stability.

Offline 3D simulation & safety algorithms: Integrated Pando 3D simulation software supports offline programming with timeline- and spreadsheet-based motion editing, rehearsal, collision checks, intelligent over-limit alerts and automated correction, reducing on-site tuning time.

Interfacing & show integration: Native DMX512 triggering, fiber-optic master links (>500 m), and wireless real-time operation with instant fault alarms via mobile, tablet, or PC — ensuring flexible and responsive system control.

Preset motion library: Common motion presets (vertical lift, wave, ripple, spiral ascent, etc.) to accelerate programming and repeatability.

4. Safety & Quality Assurance

A three-layer protection strategy was implemented:

Mechanical layer (physical redundancy): load cells, 4-point limit switches, dual brakes, overload protection, redundant primary/secondary suspension points, and G80 chains (SF12). Mechanical-level faults trigger mechanical braking or power cutoff.

Software layer (logical safeguards): preset motion limits, Pando offline collision detection, over-limit detection & auto-correction, continuous monitoring and logging— ensuring all movements execute strictly within defined safety constraints.

Control layer (operation & emergency response): “Black Warrior” control console provides emergency stop circuits (supporting Category 0 & 1 stops), real-time monitoring interface and hierarchical fault-alarm system for immediate intervention.

Implementation approach:

The control strategy incorporates real-time load monitoring for automatic fine-tuning and anomaly alerts. Each unit undergoes multiple rounds of performance and safety testing — including dynamic load tests and synchronized interruption response tests — prior to delivery. After on-site integration, standardized operation guidelines and training sessions are provided through detailed instruction materials and live demonstrations, ensuring the system’s traceability and reproducibility throughout touring operations. 

5. On-stage Presentation & Audience Impact

The oversized ring served as the show’s visual centerpiece—its synchronized multi-point swinging, combined with dynamic lighting and on-ring title displays that progressed with the show’s segments, acted as a live program indicator for the audience.

Positioned centrally above the stage, the mechanism doubled as an LED and lighting carrier, integrating scenic motion with digital content.

Mechanical motion was tightly choreographed with LED and lighting via DMX512 and console timelines, making the machinery an active element of storytelling.

The result combined high visual impact with industrial-grade reliability suited for repeated live broadcasts and touring.

6. Client Value & Outcomes

Delivered repeatable, stable dynamic staging that significantly elevated the show’s opening impact.

Reduced operational risk and extended equipment life through real-time load balancing, high-margin component selection (SF12 chain) and a multi-layer safety architecture.

Shortened on-site debugging and improved reproducibility via model-driven control and Pando simulation.

Produced a replicable electromechanical & control blueprint for similar large-scale, multi-point touring installations.

7. Technical Snapshot (quick reference)

a) Hoisting system: 37 × C1 certified intelligent CNC chain hoists (servo drive; absolute encoder)

b) Certifications: TÜV Rheinland / BGV-C1 / CE / EN 17206

c) Control: “Black Warrior” control console (YZDITEC proprietary; 3D model-driven; EtherCAT)

d) System capacity: up to 128 control loops; manage up to 256 models (single master)

e) Precision & response: Position resolution 1 mm; time resolution 0.1 s; EtherCAT cycle 2 ms

f) Features: multi-point synchronized swinging; complex trajectory interpolation; real-time load micro-adjust; offline Pando 3D simulation & collision detection; DMX512 integration; fiber comms >500 m; wireless real-time monitoring & alarms; emergency stop (Category 0/1)

g) Testing: factory performance & safety validation; on-site commissioning and live validation (dynamic load and interruption-response tests)

8. Conclusion — Technology Empowering Performance

The Talk Show & Friends project demonstrates YZDITEC’s capabilities in large-scale CNC hoist cluster control and safety-centric engineering. By combining certified, high-margin components, a SIL3-equivalent control philosophy within “Black Warrior” console, and a robust three-tier safety architecture, we delivered a solution that preserves creative expression while minimizing risk—providing repeatable, broadcast-grade stage motion that production teams can rely on.

To see more of the live stage effects, please click the YouTube link below to watch the full video.