A project at work introduced me to the world of Variable Frequency Drive (VFD) motor speed controllers and how they work with 3 phase electric motors.  There are 100's of youtube videos and websites describing the different models of VFDs and motor combinations that provide a couple of much need features such as:

• Slow start -- currently, the on/off switch creates a huge current surge on the generator and a lot of startup torque stress on the blower itself.  By ramping up the speed slowly, the generator can keep up and far less stress is applied to the mechanical drive.
• Speed control -- currently, the RPM is not quite enough to stimulate the wind on the highest 2-3 pipes.  More air pressure is needed.  That means higher starting torque (see previous bullet).  VFDs provide a variable speed adjustment that could be used to tune in the motor RPM for the best sound output on all pipes.
• 115V to 208V 3 Phase conversion -- 115V single phase is converted to 208V, 3 phase which will drive a more efficient 3 phase motor.
• Electronic switch -- instead of a full-current line switch, an electronic front panel switch is provided that can be used to start / stop the motor.  This is safer and not prone to arcing or shorting out.

I hope to research an optimal VFD (low cost, front panel speed adjustment) and 1 HP, 3Phase motor with the right mount that will let me quickly replace the current 1HP Dayton single motor that is already in the cabinet.  This will most likely become a fall project -- as there are several parades on the calendar for this summer.  

Calliope Float Completed

The Calliope float project was completed in 2015.  Since that time, the first has been to Washington and Linton: rain or shine.  Having a roof overhead is a really good idea in Indiana where the weather can change in a half hour.


Here's a picture.