SoundForge- 555 Tone Generator

Greetings everyone welcome back. Here's something loud.

The SOUND FORGE is a 555 timer-based music box that uses a few lever switches and potentiometers to produce and modify sound.

Here, we have created this device by slightly altering an old 555 mouth organ circuit.

In monostable mode, the Timer IC is connected to four potentiometers, four lever switches, and an output speaker that is one ohm.

Sound is produced when any lever switch is turned on. Here, we can rotate the potentiometer knob in order to modulate the sound generated by the switch.

This article is about the complete build process of this project, so let's get started with the build.

Materials Required

Here are the materials used in this project:

• Custom PCB
• NE555 Timer IC SOIC8
• 10K Ohms Potentiometers
• 10K Resistors, 1206 Package
• Lever Switch
• 100nF Capacitor 1206 Package
• 10uF capacitor, 25V
• Speaker 1Ohms
• M2.5 Nut and Bolt
• 3D-printed enclosure

3D MODEL

We begin by creating a 3D model in Fusion360 for the Sound Forge Project. To do this, we added the speaker, potentiometer, and lever switch to the model first.

We designed the 95 mm by 95 mm PCB, and after that, we arranged every component on the PCB so that it looked good. We put a speaker on the right, potentiometers arranged vertically on the left, and a switch positioned horizontally on the bottom.

Just the potentiometers were positioned on the top side; the speaker and lever switch were positioned on the bottom side.

Also, we added grills and mounting holes for the speaker on the PCB.

We started with a simple PCB model and then created an enclosure to house the PCB and protect all of the electronics within.

White PLA was used to 3D print the enclosure, with a 0.6mm nozzle, 0.2mm layer height, and 20% infill.

Circuit

The circuit, which had a single 555-timer IC connected in monostable mode, was prepared next.

Here, we utilized a schematic of a 555 Mouth Organ Piano, which is rather popular, and we have created our own using its fundamental design. We added a potentiometer in place of the resistor and a lever switch in place of the tactile push buttons to modify the original schematic.

The sound generated by pressing the button in the original diagram was determined by the value of the resistor that was connected in series with the button. This resistor was replaced with a potentiometer, allowing us to adjust the resistor's value and thus modify the sound.

The speaker's negative is connected to GND, and a 10 uF capacitor was added to the output in series with the speaker's positive.

Regarding the board outline, we created the PCB for this project using the dimensions provided in the Cad file.

HQ NextPCB

After completing the PCB design, we export the Gerber data and send it to HQ NextPCB for samples.

We placed an order for a white silkscreen LED board.

After placing the order, the PCBs were received within a week, and the PCB quality was pretty great.

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PCB ASSEMBLY PROCESS

• With a solder paste dispensing needle, we added solder paste to the component pads to begin the PCB assembly process. Here, we are using standard Sn/Pb 63/37 solder paste.
• Next, we place all the SMD components in their places using an ESD tweezer.
• After that, the PCB was put on the Reflow Hotplate, which raises the PCB's temperature from below to the point at which solder paste melts and all of the components are soldered to their pads.
• Next, we install the THT potentiometers in their designated locations and use a soldering iron to solder the pads.

Switches Assembly

Following circuit assembly, we mounted the lever switch in the designated holes on the PCB using the included washer and nut.

Speaker Assembly

• The speaker assembly, which is likewise rather straightforward, comes next. Here, the speaker is installed from the bottom side of the PCB.
• Four M2.5 nuts and bolts are used to mount the speaker along with the PCB.

Switch Wiring

• The wiring of the switch was really simple; each switch has its own CON2 Port, which we attached to the PCB. All we have to do is connect the switch terminals to the PCB's CON2 port using a soldering iron and jumper wire.
• We did this process for all four switches.

Enclosure Assembly

• The circuit is now positioned above the enclosure, and the two are fastened together using four M2 screws.

Final Assembly

• Finally, we installed a DC barrel jack connection to the enclosure and linked its positive and negative terminals to the circuit input terminals. This DC barrel jack will supply the device with 12 volts.
• The assembly is now complete.

RESULT

Here's the result of this simple build: a functional, extremely loud sound box that produces a wide variety of tunes and rhythmic tones.

To operate this device, you must first flip any lever switch and then adjust the sound using any potentiometer. The user can create a variety of melodies by activating and deactivating lever switches.

Overall, this project was a success and needs no further revisions.

Special thanks to HQ NextPCB for providing components that I've used in this project, check them out for all sorts of PCB or PCBA-related services for less cost.

Thanks, and I will be back with a new project soon.