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Movie projector

 
How Products are Made: How is a movie projector made?

History

The inspiration for the development of motion pictures and projectors can be traced to a variety of sources including theaters, circuses, and magic shows. Another important factor was the understanding of the phenomenon of persistence of vision. While the process was known for hundreds of years, it was only in the early nineteenth century when Roget introduced the under-lying theory in an article that it developed popular interest. In short, persistence of vision is the phenomena in which the brain retains an image that is observed by the eyes for slightly longer than it is actually seen. Movies take advantage of persistence of vision to create the illusion of motion. When successive still frames are viewed, the brain "connects" the image and they appear to move.

During the early 1800s, hundreds of novelty devices based on this principle were introduced. Some of the most influential include the Thaumatrope and the Phenakistiscope. Dr. John Ayrton Paris is generally regarded as having invented the Thaumatrope in 1825. This device was a toy with a simple design that took advantage of persistence of vision. It consisted of a small round board with a picture on both sides. The original toy had a bird on one side and a cage on the other. The board was held at the side by two strings and when spun it appeared as though the bird was in the cage.

The Phenakistiscope was introduced in 1832 by Joseph Antoine Ferdinand Plateau. This toy was a disc with a fixed center that allowed it to be spun freely. Various images were drawn on the outer edges of the disk depicting sequential movement. The pictures were spaced evenly and slits were cut in conjunction with each. The toy was held between the user and a mirror and images were viewed reflected by the mirror. The persistence of vision created the illusion of movement. Plateau was the first to realize that there had to be a resting period between images for a perfect illusion and determined that 16 images per second was the optimum number. Other inventors introduced similar devices. In 1853, Baron von Uchatius invented a projecting Phenakistiscope by adding a lantern. This was the earliest known moving picture.

One of the most important early moving picture devices was the Zoetrope that was invented by William George Homer in 1834. This device was a rotating drum that had slits cut in its side. A strip of paper, which contained the images, was affixed to the inside and the top of the drum was open. When the drum was spun, the images appeared to move. This was by far the most popular of all these animation toys. It had the added advantage of being able to change the pictures by putting in a different strip of paper with new images. The next device that advanced the technology of animation toys was the kineograph, invented in 1868. This was essentially a flipbook that had drawings or pictures of sequential movement. When the pages were flipped, the illusion of motion was created.

In 1891, Thomas Edison introduced a mechanized version of the Zoetrope he called the Kinetoscope. While similar in principle, it had significant changes. Instead of being moved by hand, the device had a motor attached for automated movement. Also, instead of simple paper images, it utilized a film with that had pictures on it. The film was moved past a fixed light source that projected an image on the wall of a closed booth. When it was found that people would gather to watch these moving pictures, a new industry was born. In 1895, the Lumiére brothers, Auguste and Louis, introduced the Cinematograph. This device was a camera that could take pictures, process it into film and project the image. In 1896, they introduced the Vitascope, which was similar to the Kinetoscope. The primary difference was that the image could be projected onto a much larger screen.

During the course of the twentieth century, movie projector design became more complicated and sophisticated. Spools were added to make it easier for film to move past the light source. The length of movies was significantly increased, and by the 1920s sound was available. In the 1930s, color movies were introduced. The industry was revolutionized in the 1960s by the introduction of the platter that made it possible to show a long movie using a single projector. During the 1970s and 1980s, digital sound was developed. Today, movie projectors are much more impressive and functional than the early counterparts, but the basic principal by which they work remains the same.

Design

Movie projectors consist of four primary sections including the spool assembly, lamp assembly, lens assembly, and audio assembly.

Spool assembly

The primary purpose of the spool assembly is to move the film through the projector. While the motion appears continuous, there is actually a slight pause after each frame. This allows light to be passed through the image and projected on the screen. The spool assembly is made up of all the parts related to storing and moving the film. The platter, which is located on the side of the projector, consists of up to four large discs about 5 ft (152 cm) in diameter vertically stacked between 1-2 ft (30-60.1 cm) apart. Each disc is large enough to hold the length of an entire film. Since every second of film requires 24 frames, a two-hour movie can be as long as 2 mi (3.2 km) when stretched out. Therefore, films are provided to movie theaters on numerous reels that must be spliced together before being loaded on the platter.

A payout assembly on the side of the platter moves the film from the feed disc through the lamp and lens assembly and back to the receiving disc. The film has small holes on its edges that allow it to be held by specialized gears called sprockets. An electric motor turns the sprockets that cause the film to be pulled through the device. Spring-loaded rollers, called cambers, provide tension to keep the film from slipping out of the sprockets. Intermittent sprockets have been developed to pull the film one frame at a time and pause before moving again. They are timed to show 24 frames per second. The film is also stretched between two bars as it passes in front of the lens to keep it tight and aligned. Depending on the projector design, the film is passed through a sound decoding system that is located above or below the lens.

Lamp assembly

The lamp assembly includes all of the parts related to illuminating the image on the film. The key element is the light source. Modern movie projectors use a xenon bulb because they burn brightly for thousands of hours. A xenon bulb is constructed with a quartz outer shell, a cathode, and an anode. When current is applied, the bulb burns bright and hot. The bulb is located in the center of a parabolic mirror which is mounted in the lamphouse. The mirror focuses the light and reflects it onto the condenser. The condenser consists of two lenses that focus the light further and direct it to the main lens assembly. The whole setup not only intensifies the light but also the heat which is why film quickly melts if it is suddenly stopped moving through the projector. Most projectors have a cooling system because of the heat generated by the lamp.

Lens assembly

The light is next passed through the picture head and lens assembly. At the start of this section is the shutter which is a small plate that is rotates 24 times a second. Its movement is synchronized with the advancing film so that dark spaces between the frames are not seen. If the shutter was not in place, the film would appear to flicker. To further reduce flickering, some movie projectors are designed with double shutters. The light is then passed through a small metal frame called the aperture. This ensures that light only shines on the part of the film with the image and not on the sprocket holes.

Light passing through the film causes the image to be projected. The main lens first focuses this image. On most movie projectors, lenses can be removed and changed for different movies. There are primarily two types of lenses available: flat and CinemaScope. A flat lens is more suitable for comedies and dramas while a CinemaScope lens is designed for action movies. Flat lenses typically are between 1.5-1.8 in (37-45 mm) long while CinemaScope lenses are 2.8-3.3 in (70-85 mm). Some movie projectors have a turret system which contains multiple lenses that can be automatically moved into place as needed.

Audio assembly

The audio assembly is the part of the projector that gives the film sound. Two types of technologies can be used: optical or magnetic. Optical systems are the most common. They consist of a light source and a photocell. On one side of the film, a transparent line is recorded. The line varies in width depending on the frequency of sound. As it passes by the light source, varying amounts of light are passed though. A photocell located on the side of the film opposite the light source, picks up the transmitted light. This light is then converted to an audio signal that is then amplified before being sent out to the speakers. Magnetic systems have a recorder head that is in direct contact with the film. The differences in the magnetic field on the film are then converted to the audio signal. Magnetic sound systems are not used as much because they have disadvantages such as being easily damaged, more expensive and a shorter life span.

Raw Materials

Numerous raw materials are used in the manufacture of a movie projector. Aluminum alloys and hard plastics are primarily used to make the housings, sprockets, gears and other structural components. Xenon gas is used for the light bulb. Xenon is a so-called inert gas that creates a tremendous amount of light when it is exposed to an electric current. Quartz is also used to make movie projector light bulbs because it can maintain its structure at high heat better than glass. Other materials used in the construction of a movie projector include rubber, stainless steel, and glass.

The Manufacturing
Process

The major components of a movie projector, including the spooling system, the projector console, the audio reader, and the lenses, are produced by different manufacturers and typically assembled on-site at the movie theaters.

Making the main body

  • The main body of the movie projector is basically a rectangular box that houses the lamphouse, the lenses, the picture head, and the audio head. It is made from steel that is loaded onto a conveyor belt. The sheets are then placed in a die with the desired shape of the housing. A hydraulic press is then released. The punch forces the steel sheet to assume the shape of the die. The body is then removed and fitted with an adjustable base that can be changed to modify the angle of viewing.

Making the picture head

These parts are all assembled separately and then put together as a whole.

  • The picture head is the area between the lamp and the lens through which the film moves. Its housing is first formed from steel in a punch press process similar to the production of the body.
  • Then a series of sprockets and roller pads are manually screwed above and below the framing aperture. An intermittent sprocket is placed below the aperture. This sprocket is then connected to the motor which causes it to start and stop at a frequency of 24 frames per second.
  • On the other side of the film, across from the aperture, is the film gate that provides pressure to hold the film in place as the image is projected. The film gate is also formed by the punch press process. Behind the film gate is the shutter blade. This is a small metal device with blades like a fan. It rotates in front of the light condensers at a controlled rate. It is synchronized with the moving film so that dark spaces between frames are not seen.
  • The lens turret is placed in front of the aperture. This is a rotating device into which the lenses are placed. It can be moved when a different lens is desired.
  • One side of the picture head frame is fitted with a door that can be opened so that film can be loaded. The separate pieces are then assembled and the entire picture head is bolted to the main projector housing.

Making the audio head

  • The audio head is constructed in much the same way as the picture head. It is composed of a variety of sprockets and film rollers. On one side of the film path a light source is affixed. This device emits light at a specific wavelength and intensity. On the other side of the film path is a photocell that detects the amount of light that travels through the film. It is connected to a series of amplifiers that are then wired to the theater speakers. The audio head can be located above or below the picture head depending on the design of the movie projector. Like the picture head it is bolted to the main projector body.

Making the lamphouse

  • The lamphouse consists of a frame and xenon bulb. Producing a xenon bulb can be a difficult process. Since these bulbs can produce a tremendous amount of heat, their outer housing is made from quartz instead of glass. First a quartz tube is heated and air blown to create the shape required for the bulb. A metal cathode is attached on one end and an anode on the other. Air is replaced in the quartz envelope by xenon gas and the whole unit is vacuum-sealed. The rarity of xenon and the difficulty in construction makes these bulbs expensive, running anywhere from $700 to $2,000 each.
  • The bulb is then mounted in the center of an aluminum parabolic shaped mirror. This assembly is then manually attached to a metal frame. The frame has an exhaust pipe and several fans to help remove the large amount of heat generated by the bulb. Wires are hand soldered to the anode and cathode which are then connected to the power supply line. The light assembly is then put in the top of the main projection body. Within the body are the condenser lenses that help focus and intensify the light.

Making the lens

  • Lenses are produced from glass. Each movie projection lens is really composed of a number of small glass lenses that have a different magnifying effect. For each component lens, the glass is first cut to the manufacturer's specifications. The glass is then placed on an assembly line and workers polish each piece to the appropriate thickness, then treat it with a special anti-reflection coating. As many as seven component lenses might be used for a single lens system.
  • The component lenses are then fitted with metal and then placed into the lens barrel at specific intervals. This is a highly precise process done by specialized workers because the distances between the glass lenses have a profound effect on the image quality. The inside of the barrel is coated with a dark, non-reflective material. The lenses are then attached to the projector body by being screwed into the lens turret.

Making the spool assembly

  • The spool assembly begins with the construction of the solid metal frame. The typical frame consists of a tall pillar with two foot bars. Each component is placed on a conveyor belt and passed under a hydraulic punch. This punch is equipped with a sharp metal saw that will cut the proper dimensions from solid steel bars. The foot bars are then manually welded perpendicularly to the bottom of the main pillar. They are positioned such that there is about a 45-degree angle between them. A smaller metal pipe is welded between the foot bars at their midpoints to provide a more stable structure. Finally, metal plates with rubber bottoms are welded to the bottom of the pillar and foot bars to ensure that there is minimal movement during operation.
  • Separately, the support arms and accompanying parts are assembled. To one end of the steel support arm a metal bearing is attached. This bearing can spin freely. To the other end of the support arm a hole is drilled through it and an electric gear motor is fitted through. At the end of the motor is a small rubber wheel that spins. It is the motion of this wheel that creates the spinning of the platter that moves the film.
  • The support arm assemblies are then attached to the main pillar at set intervals. The arms are welded to a metal plate that is then bolted and secured to the pillar. At specific points on the main pillar, the rollers that hold and guide the film to and from the projector are attached. Sensors that monitor the speed of the platters are bolted to the pillar above each support arm to synchronize the motion of the moving film. The electronic wires are fed into a control box located at the junction between the foot and the main pillar.
  • The platters are then placed on the support arms. The platters are made of lightweight aluminum alloy. They can be cut from thick sheets of the metal. A typical dimension is 5 ft (152 cm) in diameter and 0.5 in (1.3 cm) thick. They have a circular cut in the middle that can accommodate the centerpiece. This is a circular device complete with rollers and tension bars that accepts the incoming and outgoing film. A hole is also drilled directly in the center of the platter so it can be held and moved by the bearings on the support arm.

Final assembly

  • The main projector console and the film spooling systems are delivered to the movie theatre. They are connected through an electrical cable so that they move the film in a highly controlled motion. They are then ready to be loaded with film and show a movie.

Quality Control

At each step during the production process quality control testing is done to ensure that a working movie projector is produced. Each manufacturer has their own tests specifically related to the part of the projector that they make. These tests include both visual inspection and physical measurements. For example, the lens manufacturer uses computerized laser calipers to measure the thickness of each lens produced. The lamp producers measure various characteristics of the lamps that are produced such as luminosity, heat and power consumption. The components of the main projector are then assembled, and manufacturers run a sample movie through to adjust and pacing of all the moving components and determine whether the device works properly. Even after the movie projector is assembled in the theater, technicians constantly check and adjust parts as necessary.

The Future

The future of movie projectors looks to change dramatically in the coming years. With significant advances in electronic storage mediums, film may not be used to show movies. In fact, some companies are working on a system by which movies are produced on computer hard drives. Stored in this way, movies promise to be much less expensive to distribute and display. Fewer workers could run movie theaters and the movie images will be much clearer and crisper. Currently, theaters are hesitant to adopt the new technology, but it is just a matter of time before computerized digital projectors replace movie film projectors.

Where to Learn More

Books

Barclay, S. The Motion Picture Image: From Film to Digital. Focal Press, 1999.

Case, D. Film Technology in Post Production. Focal Press, 1997.

Other

Boegner, Ray F. "Everything You Wanted to Know About Xenon Bulbs." Xenon Bulb Web Page. December 2001. <http://www.cinemaequipmentsales.com/xenon1.html>.

Boegner, Ray F. "Film Technology in Post Production." Scientific American Web Page. 1998. December 2001. <http://www.sciam.com/1998/1098issue/1098working.html>.

Harrigan. Movie Projection Lens. United States Patent 6,317,268. November 13, 2001.

[Article by: Perry Romanowski]


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WordNet: movie projector
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Note: click on a word meaning below to see its connections and related words.

The noun has one meaning:

Meaning #1: projects successive frames from a reel of film to create moving pictures
  Synonyms: cine projector, film projector


Wikipedia: Movie projector
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This article is concerned with technical aspects of moving film projection. For non-film movie projection, see digital cinema. For historical aspects, see the article history of cinema.
35 mm movie projector in operation.
35 mm movie projector with enclosed type spool boxes, optical magnetic soundheads and Xenon lamphouse

A movie projector is an opto-mechanical device for displaying moving pictures by projecting them on a projection screen. Most of the optical and mechanical elements, except for the illumination and sound devices, are present in movie cameras.

Contents

Physiology

According to the theory of persistence of vision, the perceptual processes of the brain and the retina of the human eye retains an image for a brief moment of time. This theory is said to account for the illusion of motion which results when a series of film images is displayed in quick succession, rather than the perception of the individual frames in the series.

Persistence of vision should be compared with the related phenomena of beta movement and phi movement. A critical part of understanding these visual perception phenomena is that the eye is not a camera, ie: there is no "frame rate" or "scan rate" in the eye. Instead, the eye/brain system has a combination of motion detectors, detail detectors and pattern detectors, the outputs of all of which are combined to create the visual experience.

The frequency at which flicker becomes invisible is called the flicker fusion threshold, and is dependent on the level of illumination. Generally, the frame rate of 16 frames per second (frame/s) is regarded as the lowest frequency at which continuous motion is perceived by humans. (Interestingly this threshold varies across different species; a higher proportion of rod cells in the retina will create a higher threshold level.)

It is possible to view the black space between frames and the passing of the shutter by the following technique:
Close your eyelids, then periodically rapidly blink open and closed. If done fast enough you will be able to randomly "trap" the image between frames, or during shutter motion. This will not work with television due to the persistence of the phosphors nor with LCD or DLP light projectors due to the continuity of image, although certain color artifacts may appear with some digital projection technologies.

Since the birth of sound film, virtually all film projectors in commercial movie theaters project at a constant speed of 24 frame/s. This speed was chosen for financial and technical reasons. When Warner Bros. and Western Electric were trying to find the proper projection speed for the new sound pictures, Western Electric went to the Warner Theater in LA and noted the AVERAGE speed at which films were projected there. They set that as the sound seed at which a satisfactory reproduction and amplification of sound could be conducted. There are some specialist formats (eg Showscan and Maxivision) which project at higher rates, often 48 frame/s.

Silent films usually were not projected at constant speeds [1] but rather were varied throughout the show at the discretion of the projectionist, often with some notes provided by the distributor. Speeds ranged from about 18 frame/s on up - sometimes even faster than modern sound film speed (24 frame/s). Contrary to received opinion, 16 frame/s - though sometimes used as a camera shooting speed - was dangerously inadvisable for projection, due to the high risk of the nitrate-base prints catching fire in the projector. (A dramatic rendition of a nitrate print fire and its potentially devastating effects is famously found in Nuovo Cinema Paradiso, which revolves around the goings-on of a projectionist.)

Principles of operation

35 mm Kinoton FP30ST movie projector, with parts labeled. (Click thumbnail for larger text.)

Projection elements

As in a slide projector there are essential optical elements:

Light source

Incandescent lighting and even limelight were the first light sources used in film projection. In the early 1900s up until the late 1960s, carbon arc lamps were the source of light in the almost all theaters in the world.

The Xenon arc lamp was introduced in Germany in 1957 and in the US in 1963. After film platters became commonplace in the 1970s, Xenon lamps became the most common light source, as they could stay lit for extended periods of time, whereas a carbon rod used for a carbon arc could last for an hour at the most.

Most lamp houses in a professional theatrical setting produce sufficient heat to burn the film should the film remain stationary for more than a fraction of a second. Because of this, care must be taken in inspecting a film so that it should not break in the gate and be damaged, particularly inflammable cellulose nitrate film stock.

Reflector and condenser lens

A curved reflector redirects light that would otherwise be wasted toward the condensing lens.

A positive curvature lens concentrates the reflected and direct light toward the film gate.

Douser

(Also spelled dowser.)

A metal or asbestos blade which cuts off light before it can get to the film. The douser is usually part of the lamphouse, and may be manually or automatically operated. Some projectors have a second, electrically-controlled douser that is used for changeovers (sometimes called a "changeover douser" or "changeover shutter"). Some projectors have a third, mechanically-controlled douser that automatically closes when the projector slows down (called a "fire shutter" or "fire douser"), to protect the film if the projector stops while the first douser is still open. Dousers protect the film when the lamp is on but the film is not moving, preventing the film from melting from prolonged exposure to the direct heat of the lamp. It also prevents the lens from scarring or cracking from excessive heat.

Film gate and single image

A single image of the series of images comprising the movie is positioned and held flat within an aperture called the gate. The gate also provides a slight amount of friction so that the film does not advance or retreat except when driven to advance the film to the next image.

Shutter

A commonly-held misconception is that film projection is simply a series of individual frames dragged very quickly past the projector's intense light source; this is not the case. If a roll of film were merely passed between the light source and the lens of the projector, all that would be visible on screen would be a continuous blurred series of images sliding from one edge to the other. It is the shutter that gives the illusion of one full frame being replaced exactly on top of another full frame. A rotating petal or gated cylindrical shutter interrupts the emitted light during the time the film is advanced to the next frame. The viewer does not see the transition, thus tricking the brain into believing a moving image is on screen. Modern shutters are designed with a flicker-rate of two times (48 Hz) or even sometimes three times (72 Hz) the frame rate of the film, so as to reduce the perception of screen flickering. (See Frame rate and Flicker fusion threshold.) Higher rate shutters are less light efficient, requiring more powerful light sources for the same light on screen.

Mechanical sequence when image is shown twice and then advanced.
Outer sprockets rotate continuously while the frame advance sprockets are controlled by the mechanism shown.

Imaging lens and aperture plate

A lens system with multiple optical elements directs the image of the film to a viewing screen. Different lenses are used for different aspect ratios.

Aspect ratios are controlled by the lens with the appropriate aperture plate, a piece of metal with a precisely cut rectangular hole in the middle of equivalent aspect ratio. The aperture plate is placed just behind the gate, and masks off any light from hitting the image outside of the area intended to be shown. All films, even those in the standard Academy ratio, have extra image on the frame that is meant to be masked off in the projection.

Viewing screen

In most cases this is a reflective surface which may be either aluminized (for high contrast in moderate ambient light) or a white surface with small glass beads (for high brilliance under dark conditions). Switchable projection screen can be switched between opaque and clear by a safe voltage under 36V AC and is viewable from both sides. In a commercial theater, the screen also has millions of very small, evenly spaced holes in order to allow the passage of sound from the speakers and subwoofer which often are directly behind it.

Film transport elements

Film supply and takeup

Two reel system

The two reel system is also known as a changeover system, after the switching mechanism that operates between the end of one reel and the beginning of the next. In a two reel system the feed reel has a slight drag to maintain tensioning in the film, while the takeup reel is driven with a constant tension by a mechanism that is allowed to slip.

The two reel system was almost universally used before the advent of the single reel system for movie theaters in order to be able to show feature-length films. Although one reel long-play systems tend to be more popular with the newer multiplexes, the two reel system is still in significant use to this day. The projector operator operates two projectors, threading one with the next reel while the other projector plays the current reel. As the outgoing reel approaches its end, the projectionist looks for cue marks, at the upper right corner of the picture. Usually these are dots or circles, although they can also be slashes. (Some older films have occasionally been known to have used squares or triangles, and even positioned the cues in the middle of the right edge of the picture.) The first cue appears twelve feet (3.7 m) or eight seconds at 24 frame/s before the end of the reel, and signals the projectionist to start the motor of the projector containing the incoming reel. After another ten and a half feet (3.2 m) or seven seconds at 24 frame/s, the changeover cue should appear, which signals the projectionist to actually make the changeover. When this second cue appears, the projectionist has one and a half feet (457 mm) or one second at 24 frame/s to make the changeover - if it doesn't occur within one second, the tail leader of the outgoing reel will be projected on the screen. On some projectors, the operator would be alerted to the change by a bell that operated when the feed reel rotation exceeded a certain speed (that reel rotates faster as the film is exhausted), or based on the diameter of the remaining film (Premier Changeover Indicator Pat.411992), although many projectors do not have such an auditory system.

During the actual operation of a changeover, the two projectors use an interconnected electrical control connected to the changeover button so that as soon as the button is pressed, the changeover douser on the outgoing projector is closed in sync with the changeover douser on the incoming projector. If done properly, a changeover should be virtually unnoticeable to an audience. In older theaters, there may be manually operated, sliding covers in front of the projection booth's windows. A changeover with this system is often clearly visible as a wipe on the screen.

The size of the reels can vary based on the projectors, but generally films are divided and distributed in reels of up to 2000 feet (610 m, about 22 minutes at 24 frame/s). Some projectors can even accommodate up to 6000 feet (1,830 m), which minimizes the number of changeovers in a showing. Certain countries also divide their film reels up differently; Russian films, for example, often come on 1000 foot (305 m) reels, although it's likely that most projectionists working with changeovers would combine them into longer reels of at least 2000 feet (610 m), to minimize changeovers and also give sufficient time for threading and any possibly needed troubleshooting time.

Single reel system
Christie AW3 platter, BIG SKY Industries console, and Century SA projector.

There are two largely used single reel systems (also known as long-play systems) today: the tower system (vertical feed and takeup) and the platter system (non-rewinding; horizontal feed and takeup).

The tower system largely resembles the two reel system, except in that the tower itself is generally a separate piece of equipment used with a slightly modified standard projector. The feed and takeup reels are held vertically on the axis, except behind the projector, on oversized spools with 12,000 foot (3,660 m) capacity or about 133 minutes at 24 frame/s. This large capacity alleviates the need for a changeover on an average-length feature; all of the reels are spliced together into one giant one. The tower is designed with four spools, two on each side, each with its own motor. This allows the whole spool to be immediately rewound after a showing; the extra two spools on the other side allow for a film to be shown while another is being rewound or even made up directly onto the tower. Each spool requires its own motor in order to set proper tensioning for the film, since it has to travel (relatively) much further between the projector film transport and the spools. As each spool gains or loses film, the tension must be periodically checked and adjusted so that the film can be transported on and off the spools without either sagging or snapping.

In a platter system the individual 20-minute reels of film are also spliced together as one large reel, but the film is then wound onto a horizontal rotating table called a platter. Three or more platters are stacked together to create a platter system. Most of the platters in a platter system will be occupied by film prints; whichever platter happens to be empty serves as the "take-up reel" to receive the film that is playing from another platter.

The way the film is fed from the platter to the projector is not unlike an eight-track audio cartridge. Film is unwound from the center of the platter through a mechanism called a payout unit which controls the speed of the platter's rotation so that it matches the speed of the film as it is fed to the projector. The film winds through a series of rollers from the platter stack to the projector, through the projector, through another series of rollers back to the platter stack, and then onto the platter serving as the take-up reel.

This system makes it possible to project a film multiple times without needing to rewind it. As the projectionist threads the projector for each showing, he transfers the payout unit from the empty platter to the full platter and the film then plays back onto the platter it came from. In the case of a double feature, each film plays from a full platter onto an empty platter, swapping positions on the platter stack throughout the day.

The advantage of a platter is that the film need not be rewound after each show, which can save labor. Rewinding risks rubbing the film against itself, which can cause scratching of the film and smearing of the emulsion which carries the pictures. The disadvantages of the platter system are that the film can acquire diagonal scratches on it if proper care is not taken while threading film from platter to projector, and the film has more opportunity to collect dust and dirt as long lengths of film are exposed to the air. A clean projection booth kept at the proper humidity is of great importance, as are cleaning devices that can remove dirt from the film print as it plays.

Automation and the rise of the multiplex

The single reel system can allow for the complete automation of the projection booth operations, given the proper auxiliary equipment. Since films are still transported in multiple reels they must be joined together when placed on the projector reel and taken apart when the film is to be returned to the distributor. It is the complete automation of projection that has enabled the modern "multiplex" cinema - a single site typically containing from 8 to 24 theaters with only a few projection and sound technicians, rather than a platoon of projectionists. The multiplex also offers a great amount of flexibility to a theater operator, enabling theaters to exhibit the same popular production in more than one auditorium with staggered starting times. It is also possible, with the proper equipment installed, to "interlock", i.e. thread a single length of film through multiple projectors. This is very useful when dealing with the mass crowds that an extremely popular film may generate in the first few days of showing, as it allows for a single print to serve more patrons.

Feed and extraction sprockets

Smooth wheels with triangular pins called sprockets engage perforations punched into one or both edges of the film stock. These serve to set the pace of film movement through the projector and any associated sound playback system.

Film loop

As with motion picture cameras, the intermittent motion of the gate requires that there be loops above and below the gate in order to serve as a buffer between the constant speed enforced by the sprockets above and below the gate and the intermittent motion enforced at the gate. Some projectors also have a sensitive trip pin above the gate to guard against the upper loop becoming too big. If the loop hits the pin, it will close the dousers and stop the motor to prevent an excessively large loop from jamming the projector.

Film gate pressure plate

A spring loaded pressure plate functions to align the film in a consistent image plane, both flat and perpendicular to the optical axis. It also provides sufficient drag to prevent film motion during the frame display, while still allowing free motion under control of the intermittent mechanism. The plate also has spring-loaded runners to help hold film while in place and advance it during motion.

Intermittent mechanism

The intermittent mechanism can be constructed in different ways. For smaller gauge projectors (8 mm and 16 mm), a pawl mechanism engages the film's sprocket hole one side, or holes on each side. This pawl advances only when the film is to be moved to the next image. As the pawl retreats for the next cycle it is drawn back and does not engage the film. This is similar to the claw mechanism in a motion picture camera.

In 35 mm and 70 mm projectors, there usually is a special sprocket immediately underneath the pressure plate known as the intermittent sprocket. Unlike all the other sprockets in the projector, which run continuously, the intermittent sprocket operates in tandem with the shutter, and only moves while the shutter is blocking the lamp, so that the motion of the film cannot be seen. It also moves in a discrete amount at a time, equal to the number of perforations that make up a frame (4 for 35 mm, 5 for 70 mm). The intermittent movement in these projectors is usually provided by a Maltese Cross mechanism (also known as the Geneva Mechanism).

IMAX projectors use what is known as the rolling loop method, in which each frame is sucked into the gate by a vacuum, and positioned by registration pins in the perforations corresponding to that frame.

Types of projectors

Projectors are classified by the size of the film used, i.e. the film format. Typical film sizes:

8 mm

Long used for home movies before the video camera, this uses double sprocketed 16 mm film, which is run through the camera twice. The 16 mm film is then split lengthwise into two 8 mm pieces that are spliced to make a single projectable film with sprockets on one side.

Super 8

Developed by Kodak, this film stock uses very small sprocket holes close to the edge that allow more of the film stock to be used for the images. This increases the quality of the image. The unexposed film is supplied in the 8 mm width, not split during processing as is the earlier 8 mm. Magnetic stripes could be added to carry encoded sound to be added after film development.

9.5 mm

Film format introduced by Pathé Frères in 1922 as part of the Pathé Baby amateur film system. It was conceived initially as an inexpensive format to provide copies of commercially-made films to home users. The format uses a single, central perforation (sprocket hole) between each pair of frames, as opposed to 8 mm film which has perforations along one edge, and most other film formats which have perforations on each side of the image. It became very popular in Europe over the next few decades and is still used by a small number of enthusiasts today. Over 300,000 projectors were produced and sold mainly in France and England, and many commercial features were available in the format. In the sixties the last projectors of this format were being produced. They are now collectors' items.

16 mm

This was a popular format for audio-visual use in schools and as a high-end home entertainment system before the advent of broadcast television. The most popular home content were comedic shorts (typically less than 20 minutes in length in the original release) and bundles of cartoons previously seen in movie theaters. 16 mm enjoys widespread use today as a format for short films, independent features and music videos, being a relatively economical alternative to 35 mm.

35 mm

The most common film size for theatrical productions during the 20th century. In fact, the common 35 mm camera, developed by Leica, was designed to use this film stock and was originally intended to be used for test shots by movie directors and cinematographers.

A diagram of the VistaVision format

35 mm film is typically run vertically through the camera and projector. In the mid 1950's the VistaVision[1] system presented wide screen movies in which the film moved horizontally, allowing much more film to be used for the image as this avoided the anamorphic reduction of the image to fit the frame width. As this required specific projectors it was largely unsuccessful as a presentation method while remaining attractive as filming, intermediate, and source for production printing and as an intermediate step in special effects to avoid film granularity, although the latter is now supplanted by digital methods.

70 mm

High end movie productions were often produced in this film gauge in the 1950s and 1960s and many very large screen theaters are still capable of projecting it in the 21st century. It is often referred to as 65/70, as the camera uses film 65 mm wide, but the projection prints are 70 mm wide. The extra five millimeters of film accommodated the soundtrack, usually a six track magnetic stripe. The most common theater installation would use dual gauge 35/70mm projectors.

70 mm film is also used in both the flat and domed IMAX projection system. In IMAX the film is transported horizontally in the film gate, similar to VistaVision. Some productions intended for 35 mm anamorphic release were also released using 70 mm film stock. A 70 mm print made from a 35 mm negative is significantly better in appearance than an all 35 mm process, and allowed for a release with 6 track magnetic audio.

The advent of 35 mm prints with digital soundtracks in the 1990s largely supplanted the widespread release of the more expensive 70 mm prints.

A photo of a print featuring all four audio formats (or "quad track")- from left to right, SDDS (blue area to the left of the holes), Dolby Digital (grey area between the sprocket holes), analog sound (the two white lines to the right of the Dolby Digital track), and the DTS timecode (the dashed line to the right of the analog track.)

Sound

Regardless of the sound format, any sound represented on the film image itself will not be the sound for the particular frame it occupies. In the gate of the projector head, there is no space for a reader. Consequently, all optical sound formats must be offset from the image because the sound reader is usually located above (for magnetic readers) or below (for optical readers) the projector head.

See the 35 mm film article for more information on both digital and analog methods.

Optical

Optical sound constitutes the recording and reading of amplitude based on the amount of light that is projected through a soundtrack area on a film using an illuminating light or laser and a photocell or photodiode. As the photocell picks up the light in varying intensities, the electricity produced is intensified by an amplifier, which in turn powers a loudspeaker, where the electrical impulses are turned into air vibrations and thus, sound waves. In 16 mm, this optical soundtrack is a single mono track places on the right side of the projected image, and the sound head is 26 frames after the gate. In 35 mm, this can be mono or stereo, on the left side of the projected image, with the sound head 20 frames after the gate.

The first form of optical sound was represented by horizontal bands of clear (white) and solid (black) area. The space between solid points represented amplitude and was picked up by the photo-electric cell on the other side of a steady, thin beam of light being shined through it. This variable density form of sound was eventually phased out because of its incompatibility with color stocks. The alternative and ultimately the successor of variable density has been the variable area track, in which a clear, vertical waveform against black represents the sound, and the width of the waveform is equivalent to the amplitude. Variable area does have slightly less frequency response than variable density, but because of the grain and variable infrared absorption of various film stocks, variable density had a lower signal-to-noise ratio.

Optical stereo is recorded and read through a bilateral variable area track, recorded using Dolby Stereo matrix encoding and Dolby noise reduction. Left, center, right and surround channels are matrix-encoded into these two tracks.

In the 1970s and early 1980s, optical sound Super-8 mm copies were produced mainly for airline in-flight movies. Even though technology was soon made obsolete by video equipment, the majority of small-gauge films used magnetic sound rather than optical sound for a higher frequency range.

Magnetic sound

70 mm, which had no optical sound, used the 5 millimeters gained between the 65 mm negative and the final release print to place three magnetic tracks on each side of the perforations, for a total of six tracks. Unlike all other non-double head magnetic sound, 70 mm magnetic heads are located before the gate. Until the introduction of digital sound, it was fairly common for 35 mm films to be blown up to 70 mm often just to take advantage of the greater number of sound tracks. 35 mm four-track magnetic sound was used from the 1950s through the mid 1970s for big-budget feature prints. It was of excellent quality, although somewhat prone to damage and erasure over time. As analog optical stereo gained popularity (it was also more durable and far less expensive to include on a film print), 35 mm four-track magnetic sound was increasingly only used for special road show screenings, and the development of digital sound systems made it completely obsolete.

35 mm and 16 mm each are sometimes run in sync with a separate reel of magnetic sound (known as double head projection because two reels are running on one projector in sync); the image goes through a gate while the magnetic reel passes over a sound head. Since the sound is on a separate reel, it does not need to be offset from the image. This system is usually used only for very low-budget or student productions, or for screening rough cuts of films before the creation of a final married print. Sync between the two reels is checked with SMPTE leader, also known as countdown leader. If the two reels are synced, there should be one frame of "beep" sound exactly on the "2" frame of the countdown - 2 seconds or 48 frames before the picture start.

On certain stocks of Super 8 and 16 mm an iron-oxide sound recording strip was added for the direct synchronous recording of sound which could then be played by projectors with a magnetic sound head. It has since been discontinued by Kodak on both gauges.

Digital

Modern theatrical systems use optical representations of digitally encoded multi-channel sound. An advantage of digital systems is that the offset between the sound and picture heads can be varied and then set with the digital processors. Digital sound heads are usually above the gate. All digital sound systems currently in use have the ability to instantly and gracefully fall back to the optical sound system should the digital data be corrupt or the whole system fail.

Cinema Digital Sound (CDS)

Created by Kodak and ORC (Optical Radiation Corporation), Cinema Digital Sound was the first attempt to bring multi-channel digital sound to first-run theaters. CDS was available on both 35 mm and 70 mm films. Film prints equipped with CDS did not have the conventional analog optical or magnetic soundtracks to serve as a "back-up" in case the digital sound was unreadable. Another disadvantage of not having an analog back-up track is that CDS required extra film prints be made for the theaters equipped to play CDS. The three formats that followed, Dolby Digital, DTS and SDDS, can co-exist with each other and the analog optical soundtrack on a single version of the film print. This means that a film print carrying all three of these formats (and the analog optical format, usually Dolby SR) can be played in whichever format the theater is equipped to handle. CDS did not achieve wide-spread use and ultimately failed. It premiered with the film Dick Tracy and was used with several other films, such as Days of Thunder and Terminator 2: Judgement Day.

Sony Dynamic Digital Sound (SDDS)

SDDS sound runs on the outside of 35 mm film, between the perforations and the edges, on both edges of the film. SDDS was the first digital system that could handle up to eight channels of sound. The additional two tracks are for an extra pair of screen channels (Left Center and Right Center) located between the 3 regular screen channels (Left, Center and Right). A pair of CCDs located in a unit above the projector read the two SDDS tracks. The information is decoded and decompressed before being passed along to the cinema sound processor. By default, SDDS units use an onboard Sony Cinema Sound Processor, and when the system is set up in this manner, the theatre's entire sound system can be equalized in the digital domain. In contrast, both DTS and Dolby Digital soundtracks must be passed through to standard analog cinema sound processors - which are also used for analog optical sound, so equalization of the sound remains in the analog domain. The audio data in an SDDS track is compressed in the 20-bit ATRAC2 compression scheme at a ratio of about 4.5:1. SDDS premiered with the film Last Action Hero. Sony ceased the sale of SDDS processors in 2001-2002.

Dolby Digital

Also known as Spectral Recording Digital or "SR•D." Sound is printed between the perforations and is 26 frames before the picture (the offset can be varied based on processing presets). Dolby Digital produces 6 discrete channels. In a variant called SR•D EX, the left and right surround channels can be dematrixed into left, right, and back surround, using Dolby Pro Logic. The audio data in a Dolby Digital track is compressed in the 16-bit AC-3 compression scheme at a ratio of about 12:1. The images between each perforation are read by a CCD located either above the projector or in the regular analog sound head below the film gate. The information is then decoded, decompressed, and converted to analog; this can happen either in a separate SR-D processor that feeds signals to the cinema sound processor, or SR-D decoding can be built-in to the cinema processor.

As of 2006, Dolby has discontinued sale of their external SR-D processor (the DA20), so, aside from the used market, purchasing a Dolby processor with integrated SR-D is the only way to purchase an SR-D decoder.

A consumer version of Dolby Digital is also used on most DVDs, often at higher data rates than the original film. Dolby Digital officially premiered with the film Batman Returns, but it was earlier tested at some screenings of Star Trek: The Undiscovered Country.

Digital Theater Systems (DTS)

DTS actually stores the sound information on separate CD-ROMs supplied with the film. The CDs are fed into a special modified computer which syncs up with the film through the use of DTS time code, decompresses the sound, and passes it through to a standard cinema processor. The time code is placed between the optical sound tracks and the actual picture, and is read by an optical LED ahead of the gate. The time code is actually the only sound system which is not offset within the film from the picture, but still needs to be physically set offset ahead of the gate in order to maintain continuous motion. Each disc can hold slightly over 90 minutes of sound, so longer films will require a second disc. Three types of DTS sound exist: DTS-ES (Extended Surround), an 8 channel digital system; DTS-6, a 6 track digital system, and a now obsolete 4 channel system. DTS-ES derives a back surround channel from the left surround and right surround channels using Dolby Pro Logic. The audio data in a DTS track is compressed in the 20-bit APTX-100 compression scheme at a ratio of about 4.5:1. Of the three digital formats currently in use, DTS is the only one that has been used with 70 mm presentations. DTS was premiered on Jurassic Park. A consumer version of DTS is available on some DVDs.

Leaders

Academy leader is placed at the head of release prints containing information for the projectionist and featuring numbers which are black on a clear background, counting from 11 to 3 at 16 frame intervals (16 frames in 35 mm film = 1 ft). At -12 feet there is a START frame.

SMPTE leader is placed at the head of release prints or video masters containing information for the projectionist or video playback tech. The numbers count down in seconds from 8 to 2 at 24 frame intervals ending at the first frame of the "2" followed by 47 frames of black.

Usually there's an audio POP that play 48 frames (2 seconds at 24 frame per second) before first frame of action (FFOA) that helps to sync audio and video during printing processes or postproduction.

Types of lenses and screens

Orthographic

Before the advent of certain wide screen technologies, lenses always reproduced the exact proportions of the film image onto the screen. Such lenses are relatively simple to design and manufacture. Prior to modern wide screen, the industry standard image ratio of width to height was 1.37:1.

35 mm VistaVision was a wide screen orthographic system. The wide image was obtained by running the film horizontally across the gate so that the width limitation of the film was transformed to a height limitation. See the VistaVision article for more information.

Anamorphic

Simulated wide screen image with 1.96 to 1 ratio as it would be seen in a camera viewfinder or on a theater screen
Simulated anamorphed image with 1.33 to 1 ratio (4:3) as it would appear on a frame of film

1953 saw the development of wide screen films using special lenses for filming and projection. The images on these films utilized a more squarish aspect ratio (1.18:1) in order to accommodate both magnetic and optical tracks. The wide image is compressed horizontally in half onto the film in the camera using additional cylindrical elements within the lens, with a corresponding lens used in the projector to expand the image to the wide screen. This technique is called anamorphic projection and various implementations have been marketed under several brand names, including CinemaScope, Panavision and Superscope, with Technirama implementing a slightly different anamorphic technique using vertical expansion to the film rather than horizontal compression. Large format anamorphic processes included and Ultra Panavision and Camera 65 (which was renamed Ultra panavision in the early 60s).

Fish eye with dome

The IMAX dome projection method (called "OMNIMAX") uses 70 mm film oriented to maximize the image area and extreme wide angle lenses to obtain an almost hemispherical image. The field of view is tilted, as is the projection hemisphere, so one may view a portion of the ground in the foreground. Owing to the great area covered by the picture it is not as bright as seen with flat screen projection, but the immersive qualities are quite convincing. While there are not many theaters capable of displaying this format there are regular productions in the fields of nature, travel, science, and history, and productions may be viewed in most U.S. large urban regions. These dome theaters are mostly located in large and prosperous science and technology museums.

Wide and deep flat screen

The IMAX flat screen system uses large format film, a wide and deep screen, and close and quite steep "stadium" seating. The effect is to fill the visual field to a greater degree than is possible with conventional wide screen systems. Like the IMAX dome, this is found in major urban areas, but unlike the dome system it is practical to reformat existing movie releases to this method. Also, the geometry of the theater and screen are more amenable to inclusion within a newly constructed but otherwise conventional multiple theater complex than is the dome style theater.

Multiple cameras and projectors

One wide screen development during the 1950s used non-anamorphic projection, but used three side by side synchronised projectors. Called Cinerama, the images were projected onto an extremely wide, curved screen. Some seams were said to be visible between the images but the almost complete filling of the visual field made up for this. This showed some commercial success as a limited location (only in major cities) exhibition of the technology in This is Cinerama, but the only memorable story-telling film of two made for this technology was How the West Was Won, widely seen only in its Cinemascope re-release.

While neither a technical nor a commercial success, the business model survives as implemented by the documentary production, limited release locations, and long running exhibitions of IMAX dome movies.

Three-dimensional

For techniques used to display pictures with a three-dimensional appearance, see the 3-D film article for some movie history and the stereoscopy article for technical information.

See also


References

  1. ^ Nowell-Smith, Geoffrey (ed.) The Oxford History of World Cinema, pp. 446–449. Oxford University Press: Oxford, 1996.

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