In 2010 Spring Studio won the tender for refurbishment of the Federation Bells. Key components for this work were our original design of reliable actuators to ring the bells. The bells vary from 1 Kg to 1 Tonne in weight, and about 15 Cm to 1.2 M high. The installation is at Birrung Marr in Melbourne
The original ringing system installed in 2002 ceased to function effectively. At best it was 20 % functional and kept breaking down. Spring Studio designed and built prototype actuators. We tested them using a special rig built for the purpose by our partners Considered Solutions.
We rang a small bell over 5 million times, continuously, in our workshop. After while we muffled it a bit. We measured bearing wear and found it inconsequential – so we were confident to proceed with manufacturing and installation.
Based on this we were able to offer a MTBF of greater that 12 million operations, so about 15 years daily use. Since then we have tallied and logged each and every bell strike of the Federation Bells.
185,913,569 times
The system struck 185,913,569 times (as of 2022 10 13). The actuator for Bell 27, the ‘Middle C’ of the set, just passed 15,300,136 million rings and has therefore exceeded its design life. BY ABOUT 3 MILLION OPERATIONS. I am impressed even though . . . .
We manufacture a range of actuators and a control system which allows realistic playing and control of physical automated musical instruments. The model for our system is the human musician and the system incorporates nuances of expression formerly unseen in robotic instruments.
Actuators for small bells
The smallest bells use a small actuator like the one shown above. It is about 10 cm high. A corrosion resistant non magnetic brass tube houses all moving parts including the composite hammer and stainless moving connecting rods. It features 3 axis adjustment secured with just one Nyloc bolt, important when adjusting at 6 metres above ground level.
Play like a human
Strokes have a wide range of dynamics and we can incorporate special playing techniques. Our system may be tailored to produce mute strokes, trills, ruffs and novel articulations so composers can create pieces which a human player might achieve.
This leads to a system which is ultra reliable, long-lasting and therefore is able to produce useful and regular function email reports. This sophisticated self test routine plays early every day. This is disguised as a piece of music, so visitors experience is not compromised.
Components are quick to adjust and replace and design life is typically 10 years daily use before requiring repair –(update) – although this may be an underestimate based on the current situation, as its now 12 years daily playing and no sign of a mass failure.
We standardise all parts, from self-lubricating sintered bush bearings, to brass body and engineering plastic mounts. Hammers are easily replaceable. We remotely adjust actuators using a secure protocol over the web so minor repairs can be made when the system reports a fault.
You can see and hear an installation at The Federation Bells playing original compositions from around the world. The bells ring at 8-9 am, 12.30-1.30 and 5-6pm daily at Birrung Marr near Federation Square in Melbourne so visitors have a wide range of visiting times.
