Articulated Character Head Actuation via Wireless Belt-Pack Control
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Solution Overview
Problem
Existing articulated character head costumes rely heavily on skilled performers for control, are prone to wireless transmission failures, generate noise and heat, and require significant setup, limiting their adoption in the entertainment industry.
Innovation Solution
A performer-worn control system with a processor, motor drivers, and memory that stores motion commands, allowing for local and remote control of costume features, including wireless communication and real-time data processing to ensure reliable and precise movement of character head features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If RC servos are used to articulate character head features, then the costume features can be moved and animated, but the system generates noise and heat that limits use near audience members
Solution Approach 1:
The patent extracts the harmful RC servo components (motors, amplifiers, batteries) from the character head and relocates them to a remote belt-pack worn by the performer. This separation removes the noise and heat sources from proximity to audience members while preserving the articulation capability of the head features through wireless control.
Solution Approach 2:
The patent replaces the mechanical RC servo system with a digital control system using a microcontroller, digital signal processing, and wireless communication protocols. This substitution eliminates the noisy mechanical motors and analog amplifiers while maintaining precise control over the articulation of costume features.
2Ease of operation
If wireless RC control is used to operate costume features, then remote control is enabled, but wireless transmission failures may result in unexpected character movement
Solution Approach 1:
The patent implements feedback mechanisms where the belt-pack controller continuously monitors the status of the head articulation and transmits acknowledgment signals to confirm successful command execution. This feedback loop allows the system to detect and correct transmission errors, preventing unexpected movements while maintaining remote control capability.
Solution Approach 2:
The patent incorporates error correction codes and redundant transmission protocols that prepare for potential wireless failures in advance. By encoding control signals with error detection and correction capabilities, the system can recover from transmission errors without causing unexpected character movements, thus cushioning against reliability issues.
3Adaptability or versatility
If multiple RC servos are placed in the character head to animate multiple features, then more features can be articulated, but the head becomes heavier
Solution Approach 1:
The patent extracts the heavy power sources and control electronics from the character head and relocates them to the belt-pack worn by the performer. This allows multiple articulation points in the head to be controlled without adding significant weight to the head itself, as only lightweight actuators and wiring remain in the head while the heavy components are distributed to the performer's body.
4Manufacturing precision
If skilled performers are trained to control the costume features, then precise articulation is achieved, but costs increase and widespread implementation is limited
Solution Approach 1:
The patent implements self-service automation where the belt-pack controller automatically manages the articulation of multiple head features without requiring skilled manual manipulation. The system uses sensors, microcontrollers, and automated control algorithms to manage eye movements, mouth articulation, and other features, allowing performers with basic training to achieve precise articulation that previously required highly skilled puppeteers, thereby reducing training costs and enabling wider implementation.
Data Source
AI summary
A method for operating a driven output device provided in an articulated head, mobile prop, or other object worn by a performer. The method includes providing a wearable control system, the control system including a driver for the output device, a control module, a wireless receiver, and memory. The method includes storing a set of show control commands for the output device in the memory, and receiving a show control signal with the wireless receiver from a wayside controller. The method includes operating the control module to process the show control signal, to retrieve the show control commands, and to signal the driver to drive the output device based on the commands. The commands are selected based on a character identifier stored in memory associated with the output device such as in a character head junction box, and this memory stores tuning or configuration data for the output device.