Theatre Design & Technology - Winter 2005 - 23

FIGURE 6. PINCH ROLLER 3, WITH A PAIR OF DOUBLE ROLLERS

out in my driveway with a pair of sprinkler valves at each end
acting like a four-way directional valve. By timing the flow
from the faucet into a 5 gallon pail, I determined that 12 gallons per minute were available to the system. A standard water
pressure gauge indicated 60 psi. I assembled our latest roller
set on the hose and turned the water on. With a certain stately
grace, the rollers moved down the hose to the end and, when I
reversed the flow, they came all the way back again. I also
scrunched the hose up to make a serpentine path and the rollers went back and forth as before. I was elated! Now we were
getting somewhere.
I also tried the other pinch roller designs on the lowpressure system. The triple roller version (fig. 5) also moved
well along the hose, but it tilted so that two of the rollers were
evenly aligned with the hose on the pressure side. When pressure was applied to the other side of the hose, the rollers tilted
to that side. When the rollers tilted, they raised the low-pressure side of the hose off the floor a foot or more depending on
the applied pressure. We reasoned this would make attaching
scenery more difficult and complicate the eventual shape of an
enclosing track, so, although it worked, we abandoned that
design for the roller cage.
The pair of double rollers (fig. 6) did not work at all. It
may have been that the lump that formed between the roller
sets acted like a bump in the road for the trailing rollers, while
providing little or no additional force to the leading rollers.
We abandoned that design as well.
The single pair of rollers appeared to be the best arrangement for our purposes. These tests also revealed that
whatever the design, some adjustments to the roller cage
would be necessary. When the rollers move down the hose,
they rotate in opposition to the direction of travel across the
floor. We would need to add some sort of wheels to the roller
frame to hold the rollers off the floor. Also, if the tension on both
sides of the rollers was not exactly the same, the rollers would
turn off the hose until one side was free, allowing the fluid to
pass, bringing the system to a halt. With these considerations
in mind, I produced what would become the final iteration of
the roller cage, at least for the purposes of this study.
The new design featured two pressure rollers and eight
22

W I N T E R

2 0 0 5

TD & T

FIGURE 7. PINCH ROLLER 4, WITH SINGLE PAIR OF ROLLERS

FIGURE 8. THE FINAL PINCH ROLLER DESIGN

guide rollers. The guide rollers allowed the hose to feed in and
out of the cage at any angle, but kept the hose straight between
the pressure rollers. I added eight rollerblade wheels, oriented at a 45 degree angle to the length of the hose so that the
cage would be supported in any orientation (fig. 8). The roller
cage was now rather large, ungainly and sort of whimsically
reminiscent of the Martian rovers, but it worked-on the domestic water supply system at least. I laid the hose out in several different configurations: serpentine, spiral, multiple
planes and the rollers (now affectionately called Rover) negotiated the hose with aplomb each time. If Rover met an obstruction, it stopped and the hose began moving instead. I
made a note to build some clamps to hold the ends of the hose
in place.
The question remained why it would not work on the
higher pressure of the hydraulic power unit. Without a flow
meter it was difficult to know what was going on inside the
hose when Rover stalled. Since we would ultimately need some
kind of feedback device for position metering anyway, I bit the
bullet, talked to my wife, and anteed up $1,200 out of pocket
for a Hedland Model HPDA-020, positive-displacement flow
meter with quadrature encoder output.
We had considered other options for position metering,
some rather fanciful, others practical but difficult to implement.
One idea was to build a standard incremental encoder into the



Table of Contents for the Digital Edition of Theatre Design & Technology - Winter 2005

Contents
Theatre Design & Technology - Winter 2005 - 1
Theatre Design & Technology - Winter 2005 - 2
Theatre Design & Technology - Winter 2005 - 3
Theatre Design & Technology - Winter 2005 - Contents
Theatre Design & Technology - Winter 2005 - 5
Theatre Design & Technology - Winter 2005 - 6
Theatre Design & Technology - Winter 2005 - 7
Theatre Design & Technology - Winter 2005 - 8
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