Soft Limit Controller Systems
Precision Motion Control for Entertainment Rigging Applications
The Motion Laboratories Soft Limit Controller is a scalable, wall-mounted motion control platform designed to provide accurate, repeatable position limiting for fixed-speed electric chain hoists used in entertainment, theatrical, touring, and staging environments.
Built around a PLC-driven control architecture with encoder-based positional feedback, the system allows operators to define, monitor, and recall hoist travel positions with accuracy and operational consistency.
Whether you are configuring a small venue installation or a large multi-hoist production system, the Motion Labs Soft Limit platform can be tailored to your application with flexible channel counts, operator interface options, load monitoring, SCADA integration, and custom engineering support.
Built for Real-World Entertainment Environments
Entertainment motion systems require more than basic up/down control. Productions demand repeatability, visibility, scalability, and operational confidence.
The Motion Labs Soft Limit Controller provides:
Position-based motion limiting
- Encoder feedback integration
- Modular system expansion
- Centralized operator control
- Integrated safety functionality
- Flexible control of architecture
- Support for multiple hoist configurations
The result is a system designed to simplify operation while supporting the complex requirements of modern productions.
Modular & Scalable Architecture
The Soft Limit Controller platform is modular by design and scalable in standard 8-channel increments.
Standard Configurations
- 8 Channels
- 16 Channels
- 24 Channels
- 32 Channels
Custom Systems
Custom engineered systems are available for applications requiring up to 80 channels or specialized control architectures.
This scalable approach allows productions to maintain a consistent operator experience regardless of system size while providing flexibility for future expansion.
Flexible Operator Interfaces
The Motion Labs Touch Screen Operating System (TSOS) provides an intuitive operator experience for configuration, monitoring, and system control.
7.5″ TSOS Interface
Recommendation for:
- Smaller systems
- 8 channels and below
- Compact operator stations
Features:
- Position monitoring
- Configuration access
- Channel status visibility
- Motion control functionality
12″ TSOS Interface
Recommendation for:
- Larger systems
- Grouped hoist management
- Expanded system visualization
Features:
- Increased screen real estate
- Enhanced channel organization
- Improved system visibility
- Simplified large-system operation
Our sales and engineering teams can help determine the best interface configuration for your application and operational workflow.
Integrated Load Monitoring Options
Integrated load monitoring adds another level of operational awareness and system protection.
Using load cells within the control architecture, operators can monitor real-time weight data directly through the TSOS interface.
Optional Load Monitoring Features
- Real-time load visualization
- Overweight shutdown protection
- Underweight shutdown protection
- Operator load awareness
- Integrated safety monitoring
Load monitoring can be configured for applications requiring enhanced visibility during lifting and positioning operations.
TALOS SCADA Integration
For larger or more complex systems, Motion Labs offers TALOS SCADA integration for centralized supervisory monitoring and control.
TALOS allows operators and technical personnel to oversee multiple Motion Labs systems from a unified interface while improving operational visibility across installations or productions.
TALOS Features
- Centralized monitoring
- Multi-controller visibility
- Supervisory control functionality
- Integrated fixed and variable speed system moves
- Enhanced operational awareness
- Running Sequences with hoists from any Motion Lab’s controllers
Hoist Compatibility & System Configuration
Every production environment is different. Motion Labs can assist in configuring systems around the specific hoists, workflows, and operational requirements of your application.
We regularly assist customers with:
- Hoist selection guidance
- Encoder integration
- Channel capacity planning
- Control station configuration
- System layout design
- Automation integration
- Expansion planning
- Custom engineering requirements
Whether you are upgrading an existing system or designing a new installation, our team can help configure a solution that fits your operational goals.
Dedicated Power & Control Architecture
The Soft Limit Controller system utilizes dedicated wall-mounted power and control enclosures for organized, serviceable system architecture.
Power Cabinet
Provides:
- Main disconnect
- Interlocking
- Motor protection
- Power distribution
Control Cabinet
Provides:
- PLC control hardware
- Encoder interfaces
- Optional load monitoring interfaces
- Emergency stop circuitry
- Remote connectivity
- Encoder Fly Boxes
Interface directly with hoist-mounted encoders to provide real-time positional feedback for accurate soft limit control.
Engineered for Your Application
No two productions are identical. Motion Labs supports custom engineering solutions for specialized requirements including:
- Non-standard channel counts
- Expanded architectures
- Custom hardware integration
- PLC integration
- Specialized operator stations
- Application-specific software modifications
- Integration with external automation systems
Let’s Configure the Right System Together
Choosing the right motion control system involves more than selecting a channel count. Operator workflow, hoist types, monitoring requirements, scalability, and system integration all play an important role in determining the best solution.
Our sales and engineering teams work directly with customers to help configure systems that align with their operational and technical requirements.
Speak With Motion Labs About:
System configuration assistance
- Operator interface selection
- Load monitoring options
- SCADA integration
- Hoist compatibility
- Expansion planning
- Custom engineered solutions
- Budgetary and production quotes
Ready to discuss your application?
Contact Motion Laboratories to speak with a sales engineer and begin configuring your Soft Limit Controller system.
