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Tracks and Trolleys

Trolley systems have complex design and integration requirements, with a host of issues that demand meticulous attention to detail from an experienced manufacturer. Stage Technologies is the market leader in the design and manufacture of multi-winch, track-and-trolley systems using onboard intelligence. We have been producing intelligent, self-driven trolley systems for a number of years resulting in a tried-and-tested design scheme that is customisable and easily scaled to any size.

The core elements of the design now comprise standard components that have been proven extensively in the field. The use of a range of standard components within the trolley enables us to ensure a robust and reliable design without the need for extensive, and expensive, research and testing.

Designs range from a trolley providing traverse/raise/lower at the control of an aerial performer, to heavy capacity trolleys that can carry up to four winches and perform multiple, consecutive rotations. We have also recently added touring track-and-trolley systems to our repertoire, developing a truss that is suitable for assembly within a single day.

Trolleys are driven directly using an onboard friction drive system, resulting in a nimble piece of machinery that can be very precisely controlled. Our trolleys are capable of running on curved track and even broken track sections, maintaining smooth and quiet operation throughout.

Our trolleys employ encoders on a par with those used in the BigTow family of winches, often with timing belts integrated into the track, meaning that positional accuracy is consistent with our award-winning winches and meets the same high standards of safety. The track is an important part of the system, utilising a busbar that contacts with ‘collectors’ onboard the trolley to transmit power and data to multiple trolleys, eliminating the need for complex cable management or heavy duty batteries. Winches placed on our trolleys are normally completed with a ‘powered diverter’, which maintains tensions on the rope regardless of its current load, allowing an ‘empty’ rope to be lowered at full speed, without the use of ‘bob weights’ or sand bags.
 


Files

Tracks and Trolleys product sheet A4 [Download]
  • Winches are based on the award-winning BigTow range.
  • Trolley drive mechanisms utilising multi-wheel, direct drive motors.
  • Onboard control and drive intelligence uses standard Siemens Simotion/Sinamics drive units.
  • Radio link systems using Siemens Scalence Ethernet-based radio link and safety systems.
  • Busbar systems use standard, high-power bus rail.
  • Friction pulley drive systems use innovative magnetic clutches and direct drive motors to enable winches to run at high speed with no load attached.
  • Trolleys can run on straight, curved or broken track sections.
  • High quality encoders and timing belts integrated into track.
  • Powered diverter maintains tension on the rope, allowing pay loads to be swapped quickly and easily.


EXAMPLE INSTALLATIONS


LOVE by Cirque du Soleil, Mirage Theatre, Las Vegas
10 trolleys on 6 separate tracks, ranging from 2-winch trolleys to 4-winch trolleys with rotate.

Zaia by Cirque du Soleil, The Venetian, Macau
4 x 2-winch trolleys and 6 x 2-winch trolleys complete with rotation on 2 straight tracks and one oval track

Viva ELVIS by Cirque du Soleil, City Centre, Las Vegas
4 x 2-winch trolleys and 1 x 4-winch trolley complete with rotation on 3 tracks

The Dancing Water Theater, Dragone, City of Dreams, Macau
40 single-winch trolleys on 20 separate tracks (up to 40 performers in the air at one time on this system)

Film-based production, Dolby Theatre, Los Angeles
4 single-winch trolleys on 2 tracks, track system built into truss with catwalk and designed for quick assembly (1-day installation), trolley for single travelling lighting unit
 

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