Music Box Player Project

555 Timer based Music Box Player by Francis Bauer
Project description:
This project was inspired upon hearing about the 555 Timer contest and having recently seen some videos on YouTube regarding do-it-yourself music box kits. The video that I first looked at was Mbius Strip Music Box Experiment which had me looking for music box kits that use paper strips to play music. I found some at TinToyArcade.com and made an order. Upon receiving the music box kit and playing around with it, I decided to make an electronic version using 555 Timers for the contest and for the fun of it.
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27 February 2011

Quick links to documentation sections:
Paper Strip Reader Assembly / Construction Individual 555 Oscillator Circuit Schematic Overall Schematic Component List Circuit Adjustments/Calibration MusicBoxPlayer Video Future Enhancements Project Conclusion Sample Paper Music Strips MusicBoxPlayer Breadboard (Image) MusicBoxPlayer Breadboard (High Res. Image)
The project consisted of two major parts: 1. A paper strip reader suitable to interfacing with electronics. 2. Electronics capable of producing a 2 octave musical scale (15 notes).
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27 February 2011

Paper Strip Reader Assembly/Construction:
The first challenge was creating a mechanism for electronically reading the paper strips similar to the ones the mechanical music box kits used. The original music box strips have a .08 vertical distance between each of the 15 musical notes (2 octaves). I ended up having to digitize the paper strips and use Photoshop to increase the vertical distance to .1 (a 125% vertical increase). This allowed me to utilize normal .1 spaced electronic devices and protoboards. The included hole-punch in the music box kit made it relatively easy to punch the new enlarged paper strips. I had some 3mm Phototransistors in my electronics stash, which after some grinding their edges with a dremel tool I was able to have the Phototransistors spaced .1 apart. The Phototransistors I used sense visible to infra-red light so I was able to use some high intensity Red T1 LEDs as the light source to shine through the paper strip holes. Using the T1 sized LEDs allowed me to use one LED per every 2 Phototransistors, since the LEDs had a 20 viewing angle. Using 2 protoboards I wired up the LEDs on one board and the Phototransistors on the other along with their pull-up resistor networks. I made aluminum panels to hold the 2 protoboards an appropriate distance apart. Figure 1 shows a close-up of the completed assembly.
Figure 1 Page 3 27 February 2011

Music Box player electronic circuit:
Since the project was for the 555 Timer contest, the plan was to use 555 Timers to produce the needed musical tones. Since time was short I decided to just be satisfied with a simple 50% duty cycle square wave tone output from the 555 Timers. The following shows the basic 555 astable oscillator circuit I used for each of the 15 musical tones and the Rb resistor value that was used.
555 Timer IC designation U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 U11 U12 U13 U14 U15
Music Key C6 B5 A5 G5 F5 E5 D5 C5 B4 A4 G4 F4 E4 D4 C4
Frequency (Hz) 1046.502 987.767 880.000 783.991 698.456 659.255 587.330 523.251 493.883 440.000 391.995 349.228 329.628 293.665 261.626
Rb resistor Value (Ohms) 62k 62k 62k 62k 100k 100k 100k 120k 120k 150k 180k 220k 220k 220k 270k
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27 February 2011
Schematic 1
Each of the 15 musical tones has a circuit similar to the one shown in Schematic 1. The only differences between each of the circuits is the total resistance used to charge the 555 Timer timing capacitor. The Reset input on each 555 is used to turn on and off the musical tone and is connected to a phototransistor/transistor pair. So when a hole is detected on the paper strip the appropriate musical tone circuit is enabled.
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27 February 2011

Here is the overall Music Box Player schematic, which you can click on to see a larger version:
Schematic 2
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27 February 2011
Component list
Description Audio amp. Vcc filter capacitor Audio amp. Filter capacitor Audio amp. output filter capacitor U1-U15 (pin 5) control voltage U1-U15 timing capacitors (with good tolerance & temperature specs) 15 Cn .01F Vcc filter capacitor (1 per U1-U15) Note: The working voltage of the capacitors are not critical, 2x Vcc or larger should be fine. 8 LED1-LED8 Red 15 LED9-LED23 Red LM386 20k w 50k w Any T1high intensity LED will work as long as their wavelength is within the (PT) phototransistors spectral range and they have at least a 20viewing angle. Any LED will work and are only needed if you want to see each musical note triggered/played. Audio Power Amplifier IC Trim potentiometer Trim potentiometer (U1-U15 timing capacitor charge resistor) Quantity 1 1 1 15 15 Designation(s) C1 C2 C3 Ca Cb Value .1F .047F 220F .01F .01F
1 1 15
OP1 P1 Pn
3mm NPN phototransistors (400-1200nm spectral range) (visible to infra-red) Note: Pretty much any 3mm phototransistor could be used, just ensure that your LEDs output is within the spectral range of the phototransistors.
15
PT1-PT15
PT202C (Everlight)
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27 February 2011

Quantity 8 30 15 1 15 15 1 1 15 15 Designation(s) R1-R8 R9-R38 R39-R53 R54 Ra Rb SP1 SW1 T1-T15 U1-U15 Value 330 w 1k w 1M w 10 w 1k w (see table) 8 SPST 2N2222 NE555 Description LED current limiting (Discrete resistors or DIP/SIP network resistors could be used.) Transistor collector pull-up (Discrete resistors or DIP/SIP network resistors could be used.) U1-U15 output summing (Discrete resistors or DIP/SIP network resistors could be used.) Audio Amp. filter resistor U1-U15 output pull-up U1-U15 timing capacitor charge resistor Any speaker of 1w or greater Audio Amp. mute switch NPN transistors 555 timers IC (Or use 8 556 dual timers)
Additional items: Depending on how you put the circuit together you may need 8 or 16 pin IC sockets for the NE555 timers and/or DIP resistor networks. I used 16 pin wire-wrap sockets and SIP sockets when constructing the LED/Phototransistor assembly. This allowed me to easily insert the LEDs and Phototransistors as well as the DIP resistor networks I used.
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27 February 2011
Image of MusicBoxPlayer Breadboard

(Click image for High Res. Version)
Figure 2
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27 February 2011

Circuit Adjustments/Calibration:
I used a frequency counter to measure and adjust the frequency of each circuit to be as close as possible to the desired musical tone frequency. Of course as temperature changes, the frequency output of each of the circuits change so over time there are some changes in the musical tones. I imagine the original mechanical music box has an advantage in that its metal based tuning fork mechanism is much less sensitive to temperature changes so its musical tones dont change as much.
Future Enhancements:
Currently the Music Box Player requires someone to manually pull the paper music strip through the paper strip reader. I ran out of time to add a 555 circuit to control a motor and create a motor drive assembly to automatically feed the paper music strips. I envision adding an additional phototransistor to the strip reader that will detect a start/stop hole punched into the paper music strip. This additional hole could also be used as a master on/off music output control so that the musical tones are only generated when a paper music strip is inserted into the Music Box Player. Other enhancements could include the addition of some active or passive filters on the output of each of the oscillators to convert the square wave into something more sinusoidal.
Conclusion:
The prototype breadboard of the Music Box Player worked reasonably well and will eventually get built using a custom printed circuit board or at least using a hand soldered vector board. With 15 musical tones you can create many different songs to be played on the Music Box Player of almost any length by using longer and longer paper music strips. You could even connect the paper music strips ends together for continuous playback or even make a paper music strip version of the unique physical media winding method used in old 8-Track audio tapes. Anyone up for making a Music Box Player covering all 88 Piano keys/tones using 555 Timers
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27 February 2011

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555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

Figure 1 Page 3 27 February 2011

555 Timer based Music Box Player by Francis Bauer

555 Timer IC designation U1 U2 U3 U4 U5 U6 U7 U8 U9 U10 U11 U12 U13 U14 U15

555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

555 Timer based Music Box Player by Francis Bauer

Image of MusicBoxPlayer Breadboard

555 Timer based Music Box Player by Francis Bauer

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