Beckhoff Automation brings industrial muscle to the art of live entertainment

In the modern visitor attractions and live entertainment industry, the bar for "wow" is constantly rising. Audiences expect total immersion, seamless synchronisation, and dynamic environments that evolve before their eyes.

Whether it is a theme park dark ride, a transforming theatre, or a stadium concert, the magic depends on technology that must be invisible, instant, and, most importantly, safe.

While creative vision drives the industry, the engineering needed to implement it is becoming more complex. This is where Beckhoff Automation comes in. A global leader, Beckhoff takes the strict standards of industrial manufacturing and applies them to the stage.

Reliability for live events & attractions

Founded in 1980 by Hans Beckhoff, the company has expanded from a local electrical business in Verl, Germany, into a global technological leader employing over 5,300 people.

By championing PC-based control and the ultra-fast EtherCAT communication standard, Beckhoff provides the entertainment sector with the one thing it cannot compromise on: absolute reliability when the curtain rises.

"When you choose Beckhoff, you are choosing industry-proven, reliable, and durable control technology that guarantees 24/7 operation but also covers all necessary communication interfaces for the entertainment industry ", says Michel Matuschke, entertainment industry manager at Beckhoff Automation.

The traditional division between audiovisual (AV) systems and stage automation is breaking down. Lighting, sound, projection, and kinetics are no longer isolated; they now form part of a single, coordinated performance.

Beckhoff’s open PC-based control technology serves as the link between these domains.

Unlike proprietary "black box" controllers, Beckhoff’s solutions use standard IT technologies and the EtherCAT industrial Ethernet system.

This enables real-time communication and synchronisation across all devices, from safety stops to DMX lighting triggers, ensuring a fireball bursts at the exact millisecond a drum is struck.

Setting the stage on fire

There is arguably no environment more challenging for automation equipment than a touring heavy metal concert.

For the band Disturbed’s Take Back Your Life tour, the visual demands were exceptionally high. The band chose not to use traditional video screens, opting instead for fire effects as the main visual feature.

Image Engineering, a special effects firm based in Maryland, was tasked with creating the "Fire Snake"—a system of propane-powered burners capable of generating a continuous, 11-foot wall of fire and rolling fireballs.

The challenge was formidable. The rig needed to be modular for transport, endure the rigours of the road, and synchronise perfectly with the music. If the automation drifted by even a few milliseconds, the effect would be lost on the audience.

Moreover, the system had to function in extreme conditions, including rooftop concerts in Las Vegas, where temperatures reached 49°C (120°F).

Image Engineering utilised Beckhoff’s CX5140 and CX8190 Embedded PCs with TwinSAFE safety technology. The result was a system capable of creating dynamic, shape-shifting fire effects, controlled by a custom truss structure.

For the tour crew, EtherCAT offered clear and immediate advantages. Allowing the team to easily check the Fire Snake’s HMI to identify connected nodes, as EtherCAT accurately pinpoints the source of any problem.

What used to take hours to resolve now only takes minutes.

Flexibility at the Perelman Performing Arts Center

While rock concerts require rugged durability, modern performing arts centres require intelligent flexibility. The Perelman Performing Arts Center (PAC NYC), situated on the World Trade Center campus, exemplifies civic healing and architectural innovation.

The venue boasts three performance spaces that can be combined or separated into over 60 different configurations. Walls move, floors shift, and performers fly through the air. The automation system needed to handle this complexity while maintaining absolute safety for cast and crew.

The Chicago Flyhouse, Inc. adopted a distributed control system called "Mom-and-Kid." A central server functions as the "Mom," communicating with over 30 "Kid" modules—each fitted with a Beckhoff CX9020 Embedded PC and EtherCAT I/O.

This modular setup enables technicians to relocate hoists and winches anywhere within the building, connect them, and have the system automatically recognise them through Hot Connect functionality.

Safety is the critical piece of the puzzle. Because the room layouts change, safety zones must adapt dynamically. A control console should not be able to move a wall if the operator cannot see it.

Each Kid module from Flyhouse features a Beckhoff CX9020 Embedded PC with EtherCAT and TwinSAFE terminals so that it can be used in concert with other modules or standalone

By using TwinSAFE (Beckhoff’s integrated safety solution), safety data is transmitted over the same EtherCAT network as standard communication. This eliminates the need for separate wiring, allowing E-stops to immediately halt motion across combined spaces.

In both the Fire Snake and PAC NYC examples, safety was not an add-on; it was integrated into the core architecture. Beckhoff’s TwinSAFE technology enables safety logic (like emergency stops, safety doors, and speed monitoring) to run on the standard network.

For the visitor attractions industry, where ride vehicles carry passengers, and animatronics operate near guests, this integration is essential.

It reduces cabling complexity and enables sophisticated safety logic that can respond to different show modes—something that hardwired safety relays simply cannot achieve.

Democratising high-end automation with Beckhoff

A common misconception is that industrial-grade automation is only for mega-projects.

However, Beckhoff is actively broadening its portfolio to support cost-effective applications without compromising performance. As regional venues, museums, and mid-scale attractions face tighter budgets but higher visitor expectations, this shift is becoming critical.

The newly launched Economy Drive System is revolutionary for smaller attractions, animatronics, and conveyor systems. It includes the AM1000 servomotor, the AX1000 servo drive, and the AF1000 variable-frequency drive.

These parts provide a cost-effective performance while maintaining the advantages of the TwinCAT automation software platform.

The system brings together several innovative features to simplify installation and operation. One Cable Technology (OCT) enables power and feedback signals to be transmitted over a single cable, significantly reducing installation time and material costs.

Its ultra-compact footprint is ideal for applications where space is limited, such as when technology needs to be concealed within scenery or ride vehicles.

Additionally, the motor’s electronic nameplate enables the drive to automatically configure itself, making commissioning a simple, plug-and-play process.

Furthermore, the Next multi-touch panel PCs are enhancing the Human-Machine Interface (HMI). By integrating PC control and the touchscreen into a single device, Beckhoff reduces cabling and complexity.

These panels, powered by the latest Intel Atom or Arm processors, offer the computing power needed for complex visuals and diagnostics right at the operator's fingertips.

Plus, the I/O terminal has been upgraded. The new ED series EtherCAT terminals feature app-based diagnostics and tool-free push-in wiring, making maintenance quicker and simpler for technicians working in dark, confined server rooms typical of attractions.

"We have funnelled over 20 years of experience and a passion for drive technology into our new economy drive system, offering reliable performance and quality at an optimised price/performance ratio for price‑sensitive and emerging markets", says Matuschke.

Futureproofing the experience

The pace of innovation in the attractions industry is fast. Technologies that are cutting-edge today could become standard tomorrow. Beckhoff’s philosophy emphasises backward compatibility and open standards.

As demonstrated with the PAC NYC, a scalable platform means venues are not locked into a "rip-and-replace" cycle. Technicians can easily swap a device or update software to add new capabilities.

The use of EtherCAT P, which combines communication and power in a single 4-wire cable, further simplifies the infrastructure for future expansions.

The EtherCAT terminals have been upgraded in terms of technology and appearance with the ED series

Beckhoff’s origins lie in the family-owned electrical business started by Arnold and Elisabeth Beckhoff in 1953, but its focus is clearly on the future.

With over 650 developers working on concepts like machine vision, artificial intelligence, and levitating transport systems (XPlanar), the tools available to attraction designers are growing rapidly.

Beckhoff Automation shows that reliability is the most crucial element of any production, whether it's a quiet event in a New York theatre or a roaring rock concert, emphasising that, in this industry, the show must go on.

Meet the team at ISE 2026

All of these technologies come together at Integrated Systems Europe (ISE) 2026, where Beckhoff will be exhibiting from 3 – 6 February 2026 in Barcelona.

At Hall 5, Booth 5H390, visitors can see how open, PC-based control bridges the gap between AV, stage automation, lighting, safety, and motion on a single deterministic platform.

For system integrators, attraction designers, consultants, and venue operators, the Beckhoff booth offers a chance to move beyond product brochures and explore real-world architectures that are already supporting some of the world’s most demanding live entertainment projects.

Whether visitors to the booth aim to synchronise media and motion down to the millisecond, simplify safety without losing flexibility, or future-proof a venue against ongoing creative changes, Beckhoff’s engineers will be available to demonstrate how industrial-grade automation turns bold ideas into reliable, consistent results.

Beckhoff shows that in an industry where downtime affects immersion, and safety is crucial, industrial technology is essential for modern entertainment.