[Matt] works at a neon sign power supply company. When a vendor error left him with quite a few defective high voltage transformers, he couldn’t bring himself to toss them in the bin. [Matt] was able to fix the transformers well enough to work, and the idea for a high voltage keyboard began to brew. Unfortunately, the original transformers were not up to the task of creating a musical arc. At that point the project had taken on a life of its own. Matt grabbed some higher power transformers and started building.
The keyboard has 25 keys, each connected to an individual high voltage circuit with its own spark gap. The HV circuit is based upon a IR2153D self-oscillating half-bridge driver. (PDF link). The 2153D is modulated by a good old-fashioned 555 timer chip. No micros in this design, folks! The output of the IR2153D switches a pair of N-channel MOSFETS which drive the flyback transformers.
[Matt] created 25 copies of his circuit and built them up on individual PCBs. He assembled everything on a wooden board shaped roughly like a grand piano. The final project looks great – though [Matt] admittedly has no musical ability, so we can’t hear AC/DC flying out of those spark gaps just yet.
If you do want to hear sparks playing music, check out the OneTesla project we saw at MakerFaire NY 2013.