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 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, absolute care must be taken in inspecting a film so that it should not break in the gate and be damaged, particularly necessary in the era when flammable cellulose nitrate film stock was in use.
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 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 frame advance If a roll of film is continuously passed between the light source and the lens of the projector, only a continuous blurred series of images sliding from one edge to the other would be visible on the screen. In order to see an apparently moving clear picture, the moving film must be stopped and held still briefly while the shutter opens and closes. The gate is where the film is held still prior to the opening of the shutter. This is the case for both filming and projecting movies. A single image of the series of images comprising the movie is positioned and held flat within 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. The intermittent mechanism advances the film within the gate to the next frame while the shutter is closed. Registration pins prevent the film from advancing while the shutter is open. In most cases the registration of the frame can be manually adjusted by the projectionist, and more sophisticated projectors can maintain registration automatically.
Shutter It is the gate and shutter that gives the illusion of one full frame being replaced exactly on top of another full frame. The gate holds the film still while the shutter is open. 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.
Imaging lens and aperture plate : 400 mm) A projection
objective with multiple optical elements directs the image of the film to a viewing screen. Projector lenses differ in
aperture and
focal length to suit different needs. Different lenses are used for different aspect ratios. One way that aspect ratios are set is 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. Using an aperture plate to accomplish a wider aspect ratio is inherently wasteful of film, as a portion of the standard frame is unused. One solution that presents itself at certain aspect ratios is the
two-perf pulldown, where the film is advanced less than one full frame in order to reduce the unexposed area between frames. This method requires a special intermittent mechanism in all film-handling equipment throughout the production process, from the camera to the projector. This is costly, and prohibitively so for some theaters. The
anamorphic format uses special optics to squeeze a high aspect ratio image onto a standard Academy frame thus eliminating the need to change the costly precision moving parts of the intermittent mechanisms. A special anamorphic lens is used on the camera to compress the image, and a corresponding lens on the projector to expand the image back to the intended aspect ratio.
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). A 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 In the two-reel system the projector has two reels–one is the feed reel, which holds the part of the film that has not been shown, the other is the takeup reel, which winds the film that has been shown. In a two-reel projector the feed reel has a slight drag to maintain tension on the film, while the takeup reel is constantly driven with a mechanism that has mechanical slip, to allow the film to be wound under constant tension so the film is wound in a smooth manner. The film being wound on the takeup reel is being wound
head in, tails out. This means that the beginning (or
head) of the reel is in the center, where it is inaccessible. As each reel is taken off of the projector, it must be re-wound onto another empty reel. In a theater setting there is often a separate machine for rewinding reels. For the 16 mm projectors that were often used in schools and churches, the projector could be re-configured to rewind films. The size of the reels can vary based on the projectors, but generally films are divided and distributed in reels of up to , about 22 minutes at 24 frames/sec). Some projectors can even accommodate up to , which minimizes the number of changeovers (see below) in a showing. Certain countries also divide their film reels up differently; Russian films, for example, often come on reels, although it is likely that most projectionists working with changeovers would combine them into longer reels of at least , to minimize changeovers and also give sufficient time for threading and any possibly needed troubleshooting time. Films are identified as single-reel
short subjects,
two-reelers (such as some of the early Laurel & Hardy, The Three Stooges, and other comedies), and
features, which can take any number of reels (although most are limited to 1½ to 2 hours in length, enabling the theater to have multiple showings throughout the day and evening, each showing with a feature, commercials, and intermission to allow the audiences to change). For some time (ca. 1930–1960), a typical showing meant a short subject (a newsreel, short documentary, a
two-reeler, etc.), a cartoon, and the feature. Some theaters would have movie-based commercials for local businesses, and the state of New Jersey required showing a diagram of the theater showing all of the exits.
Changeover systems Because a single film reel does not contain enough film to show an entire feature, the film is distributed on multiple reels. To prevent having to interrupt the show when one reel ends and the next is mounted, two projectors are used in what is known as a
changeover system. The projectionist would, at the appropriate point, manually stop the first projector, shutting off its light, and start the second projector, which they had ready and waiting. Later the switching was partially automated, although the projectionist still needed to rewind and mount the bulky, heavy film reels. (35mm reels as received by theaters came unrewound; rewinding was the task of the operator who received the reel.) The two-reel system, using two identical projectors, was used almost universally for movie theaters before the advent of the single-reel system. Projectors were built that could accommodate a much larger reel, containing an entire feature. 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. As the reel being shown 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 occasionally used squares or triangles, and sometimes positioned the cues in the middle of the right edge of the picture. The first cue appears before the end of the program on the reel, equivalent to eight seconds at the standard speed of 24 frames per second. This cue signals the projectionist to start the motor of the projector containing the next reel. After another of film is shown (seven seconds at 24 frames/sec), the changeover cue should appear, which signals the projectionist to actually make the changeover. When this second cue appears, the projectionist has , or one second, to make the changeover. If it does not occur within one second, the film will end and blank white light will be projected on the screen. Twelve feet before the
first frame of action countdown leaders have a
start frame. The projectionist positions the start frame in the gate of the projector. When the first cue is seen, the motor of the starting projector is started. Seven seconds later the end of the leader and start of program material on the new reel should just reach the gate of the projector when the changeover cue is seen. On some projectors, the operator would be alerted to the time for a change by a bell that operated when the feed reel rotation exceeded a certain speed (the feed reel rotates faster as the film is exhausted), or based on the diameter of the remaining film (Premier Changeover Indicator Pat. No. 411992), although many projectors do not have such an auditory system. During the initial 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 opening. 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. Once the changeover has been made, the projectionist unloads the full takeup reel from projector
A moves the now-empty reel (that used to hold the film just unloaded) from the feed spindle to the takeup spindle, and loads reel #3 of the presentation on projector
A. When reel 2 on projector
B is finished, the changeover switches the live show from projector
B back to projector
A, and so on for the rest of the show. When the projectionist removes a finished reel from the projector it is
tails out, and needs to be rewound before the next show. The projectionist usually uses a separate rewind machine and a spare empty reel and rewinds the film so it is
head out, ready to project again for the next show. One advantage of this system (at least for the theatre management) was that if a program was running a few minutes late for any reason, the projectionist would simply omit one (or more) reels of film to recover the time. In the early years, with no automation, errors were far from unknown: these included starting a movie that had not been rewound and getting reels confused, so they were projected in the wrong order. Correcting either of these, assuming that someone could tell that the reels were confused, required a complete stop of both projectors, often turning on the
house lights, and a delay of a minute or so while the projectionist corrected the error and restarted a projector. These highly visible gaffes, which embarrassed the theater operators, were eliminated with the single-reel and digital systems.
Single-reel system There are two widely 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 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, the payout unit is transferred 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 that 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 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/auditoriums 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
Geneva drive, also known as the Maltese Cross 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==