Select a circus winch for the movement, not for one load-capacity number. Two models with the same rated load can behave differently because of speed, acceleration, lifting height, rope reeving and controls. Start with the act: what moves, where the load goes, how many points work together and who operates the mechanism.
This sequence helps prepare a technical brief, compare models and catch limits before installation. Any configuration for lifting people needs confirmation by an engineer or responsible venue specialist with regard to the project, equipment documentation and safety requirements.
1. Describe the movement
Record the act scenario first. Specify where the performer or prop starts, where the travel ends, whether intermediate stops are needed, what acceleration the audience should see and how many mechanisms run at the same time.
Prepare these details for initial selection:
- what moves: performer, aerial apparatus, scenery or a combined assembly;
- the mass of the performer, apparatus, rigging, connectors and moving rope section;
- upper and lower points, working travel and distance to guide pulleys;
- required lifting time or maximum speed;
- number of independent points and synchronization requirement;
- number of repetitions during rehearsal and performance;
- venue conditions: indoor or outdoor use, temperature, dust, humidity;
- power supply, installation position, attachment method and service access.
A precise movement description lowers the risk of choosing a powerful but inconvenient winch, or a model without enough speed, travel or control capability.
2. Calculate the working load
Include the performer, apparatus, suspension system, pulleys, carabiners, costume elements, moving rope section and the full assembly carried by the winch. For scenery or frames, calculate the whole moving structure.
The static mass total does not equal the required load rating. Acceleration, braking, direction changes and jerks add force. Speed, acceleration, system elasticity, pulley layout and act dynamics affect the calculation. Select the margin from the calculation, not from a generic allowance.
Send the engineer: real masses, suspension layout and movement description. Do not reduce the load to get a smaller model, and do not choose load capacity by total weight alone.
3. Agree speed and smoothness
Speed shapes the act as much as the trajectory. A slow reveal needs one movement character; a dynamic vertical act needs another. Higher speed increases demands on power, braking, attachment and the whole suspension system.
The LGPC line includes several load and speed combinations:
- up to 200 kg at up to 1.5 m/s;
- up to 270 kg at up to 2.0 m/s;
- up to 500 kg at up to 1.0 m/s;
- up to 700 kg at up to 1.0 m/s;
- up to 800 kg at up to 0.8 m/s;
- up to 1000 kg at up to 0.5 m/s.
These values show available configurations, but they do not replace selection. The same speed feels different on short and long travel. The act also depends on acceleration, deceleration and stopping accuracy. A frequency inverter helps tune smooth travel when the mechanism and chosen model allow those modes.
4. Check lifting height and rope layout
The distance between end points does not show the full rope length. The layout includes the path from the winch to the first pulley, bends, drum reserve, attachment points and reeving scheme. A block-and-tackle changes travel speed, force and required rope length.
Show in the layout:
- winch and pulley coordinates;
- working travel length;
- minimum and maximum load position;
- rope entry angles on the drum and pulleys;
- places where the rope can touch structures;
- number of rope parts in the reeving.
Select the rope together with the drum and pulleys. LGPC models use steel wire ropes of different diameters, so coordinate any rope replacement with the manufacturer or responsible engineer.
5. Choose the control format
One winch with a simple movement can use a remote hand pendant. Several mechanisms may require double or triple pendants. Choose cable length from the operator position, safe zone and cable route.
Computer control fits acts that need:
- synchronized operation of several winches;
- the same trajectory from show to show;
- programmed movement sequences;
- coordination with music, lighting or stage events;
- control of individual mechanisms and groups from one interface.
Agree the control format while selecting the winch. This makes it easier to check compatibility of drives, sensors, electrics and future automation.
6. Check brakes and travel limits
When people are lifted, safety cannot rely on operator reaction or one system element. The presented LGPC models use two electric brakes, and upper and lower positions are monitored by working and emergency automatic stop devices.
When comparing models, ask:
- how many independent braking devices the system has;
- how the mechanism behaves after power loss;
- which limit devices monitor end positions;
- how the operator triggers emergency stop;
- which checks are done before commissioning;
- how staff monitor brakes and limit devices.
Separate protective components do not make a system safe by themselves. Evaluate the whole chain: winch, rope, pulleys, attachment, electrics, control logic and crew work.
7. Check venue readiness
A winch with suitable specifications may still fail the project because of size, power supply or service access. LGPC frame dimensions depend on the series: compact models start at about 750 × 500 × 360 mm, while high-capacity models can reach 930 × 730 × 530 mm. Leave space around the equipment for installation, inspection and maintenance.
Before ordering, check:
- load capacity and geometry of the attachment location;
- frame fixing method;
- voltage, available power and connection parameters;
- power and control cable routes;
- access to brakes, drum and electrical equipment;
- protection from weather and unauthorized access;
- delivery and lifting route to the installation position.
For touring use, assess kit weight, packaging, assembly speed, repeatable attachment and connector protection during transport.
8. Check kit contents and service
Compare the supplied kit, not only the mechanism. A project may require rope of the right length, pendant, power cables, fasteners, guide pulleys, control cabinet, transport packaging and installation work.
Before ordering, clarify documentation, test procedure, warranty, service interval and spare-part availability. The responsible venue employee records checks before each use, maintenance operations and the conditions that stop operation until specialist inspection.
9. Short selection algorithm
- Describe the movement: object, trajectory, travel, speed and number of points.
- Collect loads: performer, apparatus, rigging and all moving elements.
- Prepare the layout: winch position, pulleys, rope and attachment points.
- Record conditions: power, dimensions, environment and operating mode.
- Choose control: manual, grouped or computer-based.
- Agree protection: brakes, end positions and emergency stop.
- Get engineering selection: check the configuration as one system before ordering.
What to send for selection
Send the performer and apparatus mass, required height and speed, number of winches, venue layout with attachment points, power parameters, control format, operating city and project dates. A video of a similar movement or a suspension drawing will speed up selection.
Available models are listed in Winches. If a standard configuration is not enough, an engineer can select a system for the specific production.
