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.

Calliope Float Development

I've been given a tandem axle trailer frame.  This frame was under a 26ft camping trailer.  It is a lightweight frame with electric brakes. 

     It is designed to support a floor 8ft wide by 26ft long.  Sections in the frame fall about 4ft apart. 

     The frame is probably too long, but the frame can easily be shortened. 

Here is a design idea (not to scale ) for a cabin with back porch that could be built.  The calliope could be mounted under the porch and protected from the weather.

2013 a wet year

6/22/2013 : I hurried home from Indianapolis on Saturday - a few drop on the windshield.  I got to the trailer and was ready to hook up when the clouds let loose in Odon.  Elnora got a lighter dose, but the roads were too wet to travel.  So, we didn't make it to the Davies's County fair parade.

The 128th Old Settler's parade is in a few days.  The weather forecast was calling for it to be clear.  Now, the forecast indicates a chance of rain....  We'll have to wait and see and hope for the best.

Opening Day 2012

Opening Day
    We got the calliope loaded and drove out to the parade staging area. One group of kids were already singing, "Take Me Out to the Ball Park".  We fired up the generator and tried to play a few notes.  The keys stuck!  Some would lift and stop playing while others became stuck.  I inserted a small zip-tie above the key and this helped release most of the notes.  Subsequent playing seemed to improve.  But, at last, a couple of notes remained down and would not come back up.

    We shut down and headed back to the barn.   We weren't going to the ball park today...

Update (work done on 4/30/2012, posted 5/19/12):
     After looking at the construction of the calliope, I removed 4 wood screws from the top of the keyboard and was able to look down into the key-action area. An industrious mouse had been storing up cat food for the winter. 

 As pieces would slip under the key, they would not return upright and stop playing.  With an air compressor and shop-vac, ice pick, screw driver and about any other type of tool, 

Marsha and I removed the cat food, stuffed the holes with steel wool and replaced the top. 

All keys now work just fine -- and will hopefully continue to do so for the foreseeable future.

    We should be ready for the DC fair in June!

Calliope Mfgr Info

Cozatt Calliope

The Odon Calliope is a Cozatt "Air Organ" built in Danville, IL in the late 1970's.  A company brochure can be found on the web from their early days with information about their products.  Here is a link to a brochure that I downloaded:  Cozatt Calliope Info .

Odon has been visited by another calliope from Rose Hulman -- it is a Tangley model.  It is now back in Terre Haute in storage at the Institute.

Both models have the same basic parts:  A blower providing a low-pressure air source into a wind chest. From the wind chest, there are 43 valves -- each valve is activated when a corresponding key (or note) is pressed on the keyboard.  The valve allows air to travel from the wind chest through a host to the base of a pipe.

Air enters the base of a pipe and travels upward and outward to the edges where is escapes in a very thin sheet just below the opening.
 Air passing across the opening resonates at a frequency determined by the length of the pipe.  Each pipe length is 'tuned' to a corresponding note on the keyboard -- exactly like a string on a piano.

Lower bass notes correspond to longer pipes which are also larger in diameter.  The larger diameter is needed because of the size of the sound wave that is produced.  Smaller pipes are required for higher notes.

There is a complex relationship between air pressure, length of pipe, size of the opening and diameter of the pipe.  The reader can use google to learn more about this from various articles posted on the internet.

Calliopes have been built out of various materials. PVC pipe is popular among hobbyists because it is cheap and easy to work with.  One design that you might find interesting is one that I proposed here:  PVC calliope .

Dave Lynn & Dr. Selvin Passen, MD

The previous owner of the calliope was Dr. Selvin Passen, MD of Baltimore, MD.  Dr. Passen retired from medical practice and now manages investment properties in Florida, Nevada and Maryland.  We made arrangements to meet Dr. Passen in Baltimore in January, 2010.  This meeting was the result of a 2 months of email correspondance.  Dr. Passen had recently restored the Calliope after acquiring it from Reno, NV.  It was in terrible condition.  The restoration was done and the result is a beautiful instrument that functions as good as new.

The Odon Town Hall has a photo album with the original pictures of the calliope and some of the restoration steps.