sACN/DMX light bars for (improv) theater

[kindred timber]

Hi makers !
I'd like to share with you a project for making kind of a "wrestling ring" we use for battles in improv theater.
For this show, I wanted the bars of the ring being illuminated with LEDs and controlled through the same software (QLCPlus) we use for all other theater fixtures.

Each bar is made of a stand using empty 3D filament spool poured into concrete (for adding weight) and equipped with a custom PCB handling the RS485 signal (because of the 10m cable each).

• some 3D printed parts for holding the polycarbonate tube (50mm for 53mm hole).
  The principle for these bars was inspired from the Petal Lighting system.

Then 2 aluminium cast boxes where made for :

1. 230VAC to 24VDC Power supply
2. Controller box with ESP32 (ext. antenna), RS485 emitter, fuses, XLR (for wired DMX, DC/DC converter) on a custom PCB.

Unfortunately, one of the emitter didn't work at the installation for the show, I used only 2 on 4 bars 😭

Approx. cost : 300€ (and so much hours of search, design, making and light programming).

For the lighting guys :
I used 2 universes. One with an ENTTEC Pro DMX for connecting to the existing light setup (dimmer pack, LED PAR...) and an sACN universe sent via a router on stage (wired from the booth though RJ45). ESP32 connected on the Wifi network with 98% strength. 👍
One laptop with QLC+ 4.14.1, Behringer X-Touch Compact and AKAI Pro mini MK2.
Next step : add a Resolum or Madmapper software for better effect, combined with video projector (but pricey).

I have plenty of ideas for the V2 :

• Use better cables (I used cheap RJ45 cable). But that's quite expensive.
• Make new stand for bar with 3D printed part and PETAL Lighting system for quick led strip connection
• Maybe add an Ethernet port (even if I experienced no connection dropout, but who knows).

Thank you very much to any dev of this AWESOME project !!! And for members who helped me to sort out some issues with wired DMX. 💪
I so amazed by WLED and MM projects ! 😍

[tiny idol]

Why didnt you use the RS485 conversion? for my< similir setup i use normal dmx cables from the controller to the fixture. i can go 10m and then 3x 1m fixtures.

[kindred timber]

The RS485 conversion ?
For the DMX cable, how do you supply the power ?

[real ice]

where did you buy/order the tubes?

[steep night]

Enttec LED Mapper is a good choice for pixel mapping. Like other mapping software, it's got an okay range of pre loaded media. Enough to get you by but you will need to make your own for advanced customization. It has network cues, and also webcam integration. You could use black magic web presenter or some other capture card to input video if there are projected graphics you already project somewhere else. Latency is about 5 to 10ms

[kindred timber]

Here (sorry, that's in french) : https://www.decoupe-plexi-sur-mesure.com/c/barres-spheres

BTW, I almost finished V2.
I'm still waiting for the PCB to arrive but so far I'm happy with the way it goes.
I update soon.

[daring grove]

What LEDs did you use @kindred timber

Also is that one WLED controller for all of them? How does that work?

[kindred timber]

I use 24v COB RGB strip from BTLighting.
https://a.aliexpress.com/_EzV2Bca

[kindred timber]

Yes, only one controller. I set 4 segments using 4 different pins on the ESP32.
From my understanding, I could go up to 10 different segments (only 23 LEDS per segment from the controller point of view).

[daring grove]

Thanks. Do you know how many amps this strip uses? It doesn't seem to say

[kindred timber]

According to the specs : 26W/m, so 1A/m

[daring grove]

Brill thanks. What connector are you using to connect to the lights? Sorry in asking lots of questions but this is perfect for a project I'm working on

Is it just 5 pin XLR

[kindred timber]

v1 : GX12 + cheap cat5 cable
V2 : EtherCon + good EtherCon cat6 cable

[daring grove]

Interesting. What is the point in the RS485 thing for light output, can you not just pass data line? It just gets decided on the other side anyway, right?

And what is the capacitor for? Just to smooth out the 24v? Do you have a circuit map that your willing to share? It might make understanding the PCB a bit easier

[kindred timber]

I need reliable data line in environment where there are powerful spotlights driven by old dimmer packs (lot of EMI). RS485 was the perfect choice IMO.

[daring grove]

Fair

[kindred timber]

Caps are a tank of energy available for the strip because of the 10m cable

I will share drawings and STL files when it's finished (still one week of work)

[kindred timber]

I'm about ending the 4th LED bar (still printing).
Here are some pictures and drawings of the V2 which meets my expectation.
Finals steps remaining : pour concrete in the bases and print caps.

Feel free to ask if you have some questions.

[clear geyser]

Coool ! do they sell opale polycarbonate ? or did you sand them ?

[daring grove]

did you make those metal tabs or buy them?

[daring grove]

Also can EtherCon really handle the current of the strips?

[kindred timber]

I sanded them. I couldn't find ice looking ones (matchong my specs and budget)

[kindred timber]

I used old french old phone plug (T shape). 🙂

[kindred timber]

Yes, I used 3 pairs for handling the current. I have like 0,7v sag with 10m cable (1A on 3x24AWG).

[clear geyser]

was it a lot of sanding to get close to opale ?

[kindred timber]

No, you can achieve the same aspect in few minutes. For sure, it's not perfect if you look closely.

[scenic canopy]

Did you used in level shifter?

[kindred timber]

No need of level shifter with MAX485

[hardy cove]

Cool project,!
Why did you went from the isolated max485 modules to the simpler ones?

[daring grove]

@kindred timber Sorry but your the only person I've seen use a MAX485 in PCB. Did you make your own symbol/footprint thingy for the MAX485 as I cannot find them in KiCad. If so is it possible to send them?

Thanks

[kindred timber]

Hi, sorry I used EasyEDA were I found the footprint in a community library. The first one wasn't fitting percecly and I should adjust in the next version.