Keyboard Kit

David Bellknap

Electronic Keyboard (Model AK-900)

Parts

1   Circuit Board
1   Top Case
1   Bottom Case
2   Button Cushions with 12 contacts
1   Button Cushions with 2 contacts
2   Piano Cushions with 12 contacts
1   Piano Cushions with 13 contacts
3   Black Piano Key Clips
2   White Piano Key Clips with 7 keys
1   White Piano Key Clips with 8 keys
3   Switch Springs
3   Switch Ball Bearings
2   Speaker Clamps
9   Screws 0.4" x 0.1" (10mm x 2.5mm) for Circuit Board
15   Screws 0.3" x 0.1" or 0.2" x 0.1" (7.5mm x 2.5mm or 6mm x 2.5 mm) for Bottom Case, Circuit Board side, and Speaker Clamps
3   Switches (black plastic piece with metal contact)
3   Switch Covers (gray plastic piece)
4   Large Pink Buttons
4   Large Pink Button Contacts
2   Small Pink Buttons
8   Small Orange Buttons
8   Small Green Buttons
4   Medium Blue Buttons
1   Speaker, with plug-in connector to Circuit Board
1   Battery Cover
1   Battery Pad
1   AK-900 Label
1   Battery Wires, with plug-in connector to Circuit Board, short wire to battery contact spring, and long wire to batter contact clip
     

Pictures


Keyboard Circuit Board (top)


Keyboard Circuit Board (bottom)

Theory

The AK-900 electronically creates sounds that closely resemble those from traditional musical instruments. A quick look at the schematic shows that the IC 9037 is the heart of the product. The IC 9037 is specifically designed for electronic keyboard applications. It generates a 523.252 kHz signal which is used as a master timing reference for all operations. The 37 keyboard keys represent musical notes C3 (130 Hertz) to C6 (1047 Hertz). These are connected directly to the IC 9037 and may be played anytime. These tones are produced by dividing the 523.252 kHz reference down to the appropriate frequency and the adjusting the levels of the overtones based on which instrument is being played. When you play a note on an instrument the sound produced is initially rather loud then decreases with time. There are two sets of the circuits just described to allow two notes to be played at the same time; one additional notes are played the earlier notes will be discontinued. Since the two most recent notes will be the loudest, this simplification from traditional instruments (such as a piano where the strings continue to vibrate until played again) will not be easily noticed by the listener. More complex electronic instruments will have more circuitry to simulate more notes at the same time as well as more advanced techniques for producing overtones.

All of the button selections are handled using ten control lines in a matrix. A matrix is similar to the rows and columns of a table. On power-up, the rhythm is stopped, rhythm selection is set to Pop, timbre selection is set to Piano, Tempo is set to medium, and Vibrato is OFF.

Percussion (drum-like) sounds are created by playing a short pattern stored in the IC 9037's electronic memory. All four percussion sounds may be played at the same time. If the demo or one of the rhythms is selected then a much longer pattern is played from the part’s memory in a similar manner. This will include both the tone and percussion circuitry just described and will be repeated until the user presses the stop button. The tempo is adjusted by changing the rate at which this tone pattern is played from memory (by dividing the 523.252 kHz timing reference differently). The vibrato effect is created by varying the divide ratio to the tone circuitry slightly, which will vary the tone frequency and hence the pitch of the sound.

The outputs from the two tone circuits and the percussion circuits are combined. The two volume control switches adjust the strength of the tone and percussion signals before combination; weaker electrical signals will result in weaker sound waves from the speaker. The combined result is smoothed (to remove unwanted higher frequency signals that were created along with the desired tone and percussion signal), increased in strength (amplified), and applied to the speaker where it is converted from electrical waves to sound waves.

Problems

The only issue came in the form of incorrectly formed keys. The inside contacts were not large enough to reach the triggers one the circuit board. A related issue came in trying to add width to the contacts, and by trial and error going from too little, to too much, and then to the final form, that of a working keyboard.