Dinosaurs battle, graveyard bones rattle, the Wicked Witch shouts and
an evil grasshopper spouts. On the lighter side, wise-cracking birds,
singing Country Bears, time-traveling robots and a growing lineup of
diverse characters comes to life at Walt Disney World Resort via the
“magic” of Audio-Animatronics technology.
Humor, fantasy and drama are enacted daily throughout the Magic Kingdom,
Epcot, Disney’s Animal Kingdom and Disney-MGM Studios by more than 1,600
“performers” related to one another by the thread of “life” achieved
through Audio-Animatronics technology. The technology electronically
combines and synchronizes voices, music, sound effects, character movements
and other show elements. As a result, characters such as the original
graveyard ghouls in the Haunted Mansion at the Magic Kingdom or the
imposing Hopper in “It’s Tough to be a Bug” at Disney’s Animal Kingdom
can wow guests with their lifelike movements.
Audio-Animatronics development began almost 50 years ago, spurred by
Walt Disney’s desire to give life-like movement to the three-dimensional
figures that would be the stars of new Disneyland attractions -- just
as he had given life to the cartoon characters in his films.
The challenge to animate the theme-park figures fell to WED Enterprises
(now known as Walt Disney Imagineering), the Disney creative design,
development and engineering subsidiary. On staff were many of the famed
Disney animators, rich in their understanding of the basic elements
of re-creating movement.
But technology to achieve pre-programmed movement in three-dimensional
figures was in a primitive state. The earliest experiments utilized
simple mechanical devices -- cams and levers -- to animate miniature
scale model human figures such as Dancing Man, a 9-inch tall tap-dancing
vaudevillian, who was programmed to mimic the dance steps of Buddy Ebsen.
Cams were tedious to cut, and the movement they could induce was limited
to the diameter of the cams -- clearly an inadequate approach to animate
life-size figures with life-like movements and sounds.
Disney’s “Imagineers” combined the cam-and-lever principle with an
electronic-hydraulic-pneumatic approach to achieve more versatility
in the moving animals of two early Disneyland attractions, Nature’s
Wonderland and Jungle Cruise. But the actions remained simple.
Abandoning cams and levers, Imagineers -- with help from studio sound
experts and electricians -- devised a system to control the actions
by means of magnetic recording tape and solenoid coils. Signals recorded
on the tape trigger solenoid coils inside the figures, producing action.
This first “pure” form of Audio-Animatronics technology was introduced
in the summer of 1963 with the opening of the Enchanted Tiki Room at
Disneyland.
Programming life-like movements in animal characters proved easier
than in human figures. To record the sequence of signals that would
animate the human figures during playback, Wathel Rogers, “the father
of Audio-Animatronics technology,” was rigged-up with a harness-like
device. As he moved, the various actions were recorded as a series of
distinctive signals.
The programming was painstaking. For instance, a figure of Abraham
Lincoln created for the 1964 New York World’s Fair incorporated 57 moves,
including 22 different head movements, all of which had to be acted
out in correct sequence by the wired-up animator.
In 1969, Imagineers turned to the rapidly developing technology of
computers as an ally. A variety of movements are first recorded onto
a computer data disk, a process known as the Digital Animation Control
System (DACS). Animators then manipulate figure movements using a console
of buttons and knobs, enabling them to quickly insert, delete or adjust
actions.
The finished show is controlled by DACS Playback, which simultaneously
relays data and cues to speakers, lights, special effects and Audio-Animatronics
figures. As technology progressed into the 1980s, so did the control
system. Today, a control system composed of multiple DACS controls the
Audio-Animatronics figures for both Epcot and the Magic Kingdom from
a single remote location.
Sophisticated computers have enabled Audio-Animatronics animators to
achieve greater subtleties in body language and expression -- even a
pioneering walking movement by Ben Franklin during a scene of The American
Adventure at Epcot. Franklin’s head tilts and nods, his body twists,
individual fingers of his hand move, his torso moves forward and to
the side, his mouth “pinches” right and left -- some 40 separate movements
in that scene alone.
"To accomplish this, we had to push our abilities to the limit,”
Wathel Rogers observed during the show’s premier in October 1982. “When
the process was finished, we had the most complex Audio-Animatronics
figure ever built.”
That is, until Imagineers developed Audio-Animatronics A-100 technology
in the late 1980s. These state-of-the-art figures incorporate compliance
technology, which enables their movements and gestures to be even more
fluid and realistic. However, programming remains as painstaking as
ever. It generally takes about eight hours to animate one second of
movement.
The first Audio-Animatronics A-100 figure was the Wicked Witch, who
debuted in The Great Movie Ride at Disney-MGM Studios in 1989. The newest
A-100 figures include the terrifying carnotaurs in the DINOSAUR attraction
at Disney’s Animal Kingdom. The most complex A-100 figure to date is
Hopper, a nine-foot, four-armed grasshopper with 68 functions who appears
in “It’s Tough to be a Bug,” also at Disney’s Animal Kingdom. Other
A-100 figures are Bill Clinton and Abraham Lincoln in Hall of Presidents,
S.I.R. in The ExtraTERRORestrial Alien Encounter and the Timekeeper
character in Timekeeper, all at the Magic Kingdom.