PROJECT REPORT

ON
SPEED CONTROLER FOR
SMALL COOLING FAN
Submitted In Partial Fulfilment of the Requirement for the Award of

Diploma in Instrumentation &Control

Engineering
Under The Guidance Of:
Mr. Imdadullah
(Assistant Professor)
SUBMITTED BY:
MOHD SHAHNAWAZ

ELECTRICAL ENGINEERING SECTION

UNIVERSITY POLYTECHNIC
FACULTY OF ENGINEERING & TECHNOLOGY
ALIGARH MUSLIM UNIVERSITY, ALIGARH
2014-15

ELECTRICAL ENGINEERING SECTION

UNIVERSITY POLYTECHNIC
ALIGARH MUSLIM UNIVERSITY, ALIGARH

CERTIFICATE
This is to certify that the project report entitled
SPEED CONTROL FOR SMALL COOLING
FAN is a record of project work carried out by RIZWAN
DANISH for the award of DIPLOMA IN
INSTRUMENTATION AND CONTROL Engineering
accepted as partial fulfilment of the requirements of three
years Diploma in Engineering. This is a work of the student
carried out under my supervision and guidance.

EXTERNAL EXAMINER

MR. IMDADULLAH
(ASSISTANT PROFESSOR)

Dedicated To Our
Beloved Parents,
Honourable
Teachers, Lovable
Brothers and Friends
&
The Aligarh Muslim
University
For Tremendous
Contribution in
Shaping
Our Life and Career

ACKNOWLEDGEMENT
First of all, I go before the Almighty Allah, the supreme and creature
of nature and entire universe.
I express my deepest thanks and gratitude to Mr. Imdadullah,
assistant

professor,

and

electrical

engineering

section,

university

polytechnic, who gave his valuable time, suggestions and guidance time to
time during the execution of this project, without which it was unable to
complete this achievement.
I am also grateful to Mr. T.A. Abbasi, associate professor& in charge
of electrical engineering section, university polytechnic
My sincere acknowledgement goes to technical assistants Mr. Jamshed
alam and Mr. Khalid for their instructions and guidance on this project.
A work of respect and appreciation to the jury members for all they
have given to the students of this section is unforgettable.
I extend my thanks to my fellow group partners and friends for their
appreciable help and immense support during the accomplishment of this
project.
Last but not least; I express my profound love and thanks to my
parents and family for their never ending encouragement, moral support and
co-operation.

CONTENT
CHAPTER 1
page No.
1.1 Introduction
6-7
CHAPTER 2
2.1 Circuit Description
8-9
2.2 Working
9-10
CHAPTER 3
3.1 Description of Components Used
11-12
3.2 Resistor
13-14
3.3 Capacitor
15-16
3.4 NTC Thermistor
17-18
3.5 IN 4007 Diode
19-20
3.6 DC motor
3.7 Power Supply
3.8 LED

21-22
23-24
25-26

CHAPTER 4
4.1Estimating and Coasting
26-27
CHAPTER 5
5

5.1Result
28-29
CHAPTER 6
6.1Bibliography
29-30
CHAPTER 7
7.1 Soldering Technique
30-34

CHAPTER
1
INTRODUCTION

INTRODUCTION:
DC motors are used extensively in adjustable-speed
drives and position control applications.
Their speeds below the base speed can be controlled
by armature-voltage control. Speeds above the base speed
are obtained by field-flux control. As speed control method
for DC motors are simpler and less expensive than those for
the AC motors, DC motors are preferred where wide speed
7

range control is required. DC choppers also provide

variable dc output voltage from a fixed dc input voltage.
This is a simple automatic temperature controlled fan
circuit using NTC thermistor. The main component of this
temperature controlled fan circuit is a negative temperature
coefficient (NTC) which detects the temperature, a
comparator which is used compare the present temperature
value and relay circuit to driven the fan. Power supply for
this circuit is given by a step down transformer. DC motor
is controlled using thermistor by changing the temperature
of surrounding. Thus when the surrounding temperature
changes then the thermistor sense and automatically the
speed of fan is change and vice versa. The increasing and
decreasing the speed of fan is shown by LED2 when motor
run fast then LED2 is brighter and vice versa.

CHAPTER

CIRCUIT DESCRIPTION AND

WORKING
CIRCUIT DESCRIPTION
The circuit given here is of a simple automatic speed
controller 6V and 0.6W or (1.2W) cooling fan that
increases the fans speed when temperature rises and vice
versa.
Fig. 3 shows circuit diagram of the speed controller for
the small cooling fan. Resistor R1 limits the initial current
for the motor and lovers the speed of rotation, if needed the
temperature control is done by one or more NTC (negative
temperature coefficient) thermistors connected in series
with the electric motor. The number of thermistors are
depend on there power dissipation.

FIG.1: CIRCUIT DIAGRAM

PCB Layout:

FIG.2: PART PLACMENT AND PCB LAYOUT

10

WORKING
Small cooling fans are used in some equipment for cooling semi
conductor devices. The NTC thermistors are used here in parallel because
the power dissipation and self-heating of NTC are reduced. It is better to
used NTC with tolerance of 2%. The NTC are available with nominal value
of 3.3-ohm to 470 kilo-ohm and have maximum power dissipation
of 0.5W at +50*C.
The resistor R2 through R5 is equalisation and limiting resistors.
These resistor are usually between 3% and 15% of the resistance of the
thermistors at 25^C.
LED1 is used as power on/off indicator for the circuit. LED2 indicates
the speed of rotation of fan. If the speed of motor is high, LED2 glows
brightly, and vice versa. Diode D1 is used to prevent back EMF when power
supply is removed.
Connector CON1 is used for the power supply. It is better to have
power supply 10 to 25% higher than the nominal working voltage of the fan
to compensate for the voltage drop across the resistors and the thermistor.
Voltage drop across resistor R8 is proportional to the current in the motor.
Connector CON2 is used to connect a digital voltmeter to measure the
voltage drop.
Fix all the four NTC thermistor (NTC1 through NTC4) appropriate
location, within the equipment whose heat is to be dissipated, for
temperature sensing. On front panel of the speed controller fix switch S1 for
power on/off, LED2 for fan-speed indication. Before using the circuit, verify
that voltages at various points in the circuit.

11

12

CHAPTER

DESCRIPTION
OF COMPONENTS
USED

13

List of Electronic Components:

1. Resistors (10x4, 1Kx2,390x1,1x1)
2. Capacitor
3. NTC Thermistors
4. 1N4007 Diode
5. DC Motor(6volt)
6. Power supply (6volt)
7. LED

14

RESISTOR
Resistors are the most commonly used component in electronics and their
purpose is to create specified values of current and voltage in a circuit. A
number of different resistors are shown in the figures. Electrical resistance is
the property of a material which offers opposition to current and dissipates
energy. Resistors with power dissipation below 5 watt (most commonly used
types) are cylindrical in shape, with a wire protruding from ach end for
connecting to a circuit (Fig 5). Resistors with power dissipation above 5 watt
are not use in mostly cases. The symbol of resistance is shown in (FIG: 6)

FIG.3: RESISTORS

FIG.4: RESISTOR SYMBOL

15

A resistor is a passive two-terminal electrical component that

implements electrical resistance as a circuit element. Resistors act to
reduce current flow, and at the same time act to low voltage levels within
the circuits. In electronic circuit resistor are used to limit the current flow,
to adjust signal levels, bias active elements terminate transmission lines
among other users.
The unit for measuring resistance is the ohm. (The Greek letter called Omega). Higher resistance values are represented by k (kiloohms) and M (mega ohms). For example, 120000 is represented as
120k. The dot is generally omitted as it can easily be lost in the printing
process. In some circuit diagrams, a value such as 8 or 120 represents a
resistance in ohms. Another common practice is to use the letter E for
resistance in ohms. The letter R can also be used. For example, 120E
(120R) stands for 120 , 1E2 stands for 1R2 etc.

16

CAPACITOR
A capacitor is a passive electronic component that stores energy in the
form of an electrostatic field. In its simplest form, a capacitor consists of two
conducting plates separated by an insulating material called the dielectric.
The capacitance is directly proportional to the surface areas of the plates,
and is inversely proportional to the separation between the plates.
Capacitance also depends on the dielectric constant of the substance
separating the plates.

FIG.5: CAPACITOR

Fig.6: CAPACITOR CONSTRUCTIONS

17

The standard unit of capacitance is the farad. This is a large unit; more
common units are the microfarad F (1 F = 10 6 F) and the Pico farad,
abbreviated PF (1pF = 1012 F).
Capacitors can be fabricated onto integrated circuit (IC) chips. They
are commonly used in conjunction with transistors in dynamic random
access memory (DRAM). The capacitors help maintain the contents of
memory. Because of their tiny physical size, these components have low
capacitance. They must be recharged thousands of times per second or the
DRAM will lose its data. Large capacitors are used in the power supplies of
electronic equipment of fall types, including computers and their peripherals.
When there is a potential difference across the conductor, an electric
field develop across dielectric, causing positive charge +Q to collect on one
plate and negative charge Q to collect on the other plate. If a battery has
been attached to a capacitor for a sufficient amount of time no current flow
through the capacitor. An ideal capacitor is characterised by a single constant
value of its capacitance. Capacitance is expressed as the ratio of the electric
charge Q on each conductor to the potential difference V between them.
Capacitor is widely used in electronic circuit for blocking direct current
while allowing alternating current to pass.

18

NTC THERMISTOR
A thermistor is type of resistor whose resistance varies significantly
(more than in standard resistors) with temperature. The word a portmanteau
of thermal and resistor. Thermistors are widely used as inrush current
limiters, temperature sensors, self-resetting over current over current
protectors, and self regulating heating elements.
Thermistors differ from resistance temperature detectors (RTD) in that
material used in a thermistor is generally a ceramic or polymer, while RTD
use pure metals the temperature response is also different; RTD are useful
over larger temperature ranges, while thermistors typically achieve a higher
precision within a limited temperature range.

FIG.7: NTC THERMISTOR

FIG.8: THERMISTOR DIAGRAM

19

Thermistor can be classified into two types, depending on the

classification of k. if k is positive, the resistance increases with increasing
temperature, and the device is called a positive temperature coefficient
(PTC) thermistor, or posistor. If k is negative, the resistance is decreases
with increasing temperature, and the device is called negative temperature
coefficient (NTC) thermistor.
NTC thermistors are made from a pressed disc, rod, plate, bead or cast
chip of a semi conductor such a sintered metal oxide. They work because
raising temperature of semiconductor increases the no of charge carriers. It
promotes them into the conduction band. The more charge carries that
available the more current a material can conduct.
Negetive tempereture coeffecient (NTC) device are use in tempereture
sensing and are the most common type of thermistor. NTC have tempereture
that vary crosponding change in body tempreture negetive tempereture
coeffecient(NTC) thermistor exihbits a decresse in electrical resistance when
subjected to an incresse importance of the B constant value, that it is
possible to charecterise NTC thermistors using the B parameter equation;
where is resistance at a temperture by slowly warming the heater gradually
incresing current with NTC thermister included in the circuit.

20

IN 4007 DIODE
These diodes are used to convert AC into DC these are used as half wave
rectifier or full wave rectifier. Three points must he kept in mind while using
any type of diode.
1. Maximum forward current capacity
2. Maximum reverse voltage capacity
3. Maximum forward voltage capacity
The number and voltage capacity of some of the important diodes
available in the market are as follows: Diodes of number IN4001, IN4002,
IN4003, IN4004, IN4005, IN4006 and IN4007 have maximum reverse bias
voltage capacity of 50V and maximum forward current capacity of Diode of
same capacities can be used in place of one another. Besides this diode of
more capacity can be used in place of diode of low capacity but diode of low
capacity can not be used in place of diode of high capacity. For example, in
place of IN4002; IN4001 or IN4007 can be used but IN4001 or IN4002 can
not be used in place of IN4007.The diode BY125made by company BEL is
equivalent of diode from IN4001 to IN4003. BY 126 is equivalent to diodes
IN4004 to 4006 and BY 127 is equivalent to diode IN4007.

FIG.9: DIODE

A semiconductor diode, the most common type today, is a crystalline

piece of semiconductor material with a pn junction connected to two
electrical terminals. A vacuum tube diode has two electrodes, a plate (anode)
21

and a heated cathode. The first semiconductor diodes were made of mineral
crystals such as galena. Today, most diodes are made of silicon, but other
semiconductors such as selenium sometimes used.
The most common function of a diode is to allow an electric current to
pass in one direction (called the diode's forward direction), while blocking
current in the opposite direction (the reverse direction). Thus, the diode can
be viewed as an electronic version of a check valve. This unidirectional
behaviour is called rectification, and is used to convert alternating current to
direct current, including extraction of modulation from radio signals in radio
receiversthese diodes are forms of rectifiers. However, diodes can have
more complicated behaviour than this simple onoff action, due to their
nonlinear current-voltage characteristics. Semiconductor diodes begin
conducting electricity only if a certain threshold voltage or cut-in voltage is
present in the forward direction (a state in which the diode is said to be
forward-biased). The voltage drop across a forward-biased diode varies only
a little with the current, and is a function of temperature; this effect can be
used as a temperature sensor or voltage reference. Semiconductor diodes'
currentvoltage characteristic can be tailored by varying the doping,
introducing impurities into the materials. These techniques are used to create
special-purpose diodes that perform many different functions. For example,
diodes are used to regulate voltage (Zener diodes), to protect circuits from
high voltage surges (avalanche diode, to electronically tune radio and TV
receivers (varactor diodes), to generate radio-frequency oscillations (tunnel
diodes, Gunn diodes, IMPATT diodes), and to produce light (light-emitting
diodes). Tunnel, Gunn and IMPATT diodes exhibit negative resistance,
which is useful in microwave and switching circuits.

DC MOTOR
22

A motor is a machine that converts electrical energy into mechanical

energy. Motors are generally used in location where they are exposed to
dust, moisture, fumes and mechanical damage. Thus, motors require
protective enclosures for ex; drip-proof, fire proof etc according to the
requirement. DC motor as so called because they are powered by a current
placed across the electrodes of the motor. The speed rating of a DC motor is
the top speed it can run at. The actual speed the motor runs at is a function of
how strong current is applied to motor. Dc motor can run both forward and
backward depending on the direction of the applied current. DC motor come
with high speed rating, and thus very low torque. Gears and transmissions
allow us to covert the speed of a DC motor into torque that can be used for
other tasks, such as moving heavy robots.

FIG.10: DC MOTOR

23

Motor converts the electrical energy into the mechanical energy.

Speed is the maximum rotation of the motor; this is usually measured in
revolution per minute, or RPM. RPM means that the axle of motor will turn
completely around a circle once in a minute which is very slow even a very
cheap DC motor will have a speed rating at least 1000 RPM.
In any electric motor operation is based on the simple
electromagnetism. A current carrying conductor generates a magnetic field,
when this is then placed in an external magnetic field, it will experience a
force proportional to the current in the conductor and to strength of the
external magnetic field. It will experience a force proportional to the current
in the conductor, and to strength of the external magnetic field. As you are
well aware of from playing with magnets as a kid, opposite (north or south)
polarities attract, while like polarities like (north and north, south and south)
repel. The internal configuration of a DC motor is designed to harness the
magnetic interaction and an external magnetic field to generate rotational
motion.
Every dc motor has six basic parts axle, stator, commutator, field
magnets, and brushes. In small motor, an alternative design is often used
which features a coreless armature winding. This design depends upon the
coil wire itself for structural integrity. As a result, the armature is hollow,
and the permanent magnet can be mounted inside the rotor coil. Coreless DC
motors have much lower armature inductance than iron core motors motor of
comparable size, extending brush and commutator life.

POWER SUPPLY:
24

A power supply is an electronic device that supplies electric energy to

and electrical load. The primary function of a power supply is to convert one
form of electrical energy to another and, as a result, power supplies are
sometimes referred to as electric power converters. Some power supplies are
discrete, stand-alone devices, whereas others are built into larger devices
along with their loads. Examples of the latter include power supplies found
in consumer electronics devices.
Every power supply must obtain the energy it supplies to its load, as
well as any energy it consumes while performing that task, from an energy
source. Depending on its design, a power supply may obtain energy from
various types of energy sources, including electrical energy transmission
systems, devices such as a batteries and fuel cells, electromechanical
systems such as generators and alternators, solar power converters, or
another power supply.

25

FIG.11: POWER SUPPLY

FIG.12: CIRCUIT DIAGRAM

All power supplies have a power input, which receives energy from
the energy source, and a power output that delivers energy to the load.
In most power supplies the power input and output consist of
electrical connectors or hardwired circuit connections, though some power
supplies employ in lieu of galvanic connections for the power input or
output. Some power supplies have other types of inputs and outputs as well,
for functions such as external monitoring and control.
26

Power supplies are categorized in various ways, including by

functional features. For example, a regulated power supply is one that
maintains constant output voltage or current despite variations in load
current or input voltage. Conversely, the output of an unregulated power
supply can change significantly when its input voltage or load current
changes. Adjustable power supplies allow the output voltage or current to
be programmed by mechanical controls (e.g., knobs on the power supply
front panel), or by means of a control input, or both. An adjustable regulated
power supply is one that is both adjustable and regulated. An isolated power
supply has a power output that is electrically independent of its power input;
this is in contrast to other power supplies that share a common connection
between power input and output.
Power supplies can be broadly divided into linear and switching types.
Linear power converters process the input power directly, with all active
power conversion components operating in their linear operating regions. In
switching power converters, the input power is converted to AC or to DC
pulses before processing, by components that operate predominantly in nonlinear modes (e.g., transistors that spend most of their time in cut off or
saturation). Power is "lost" (converted to heat) when components operate in
their linear regions and, consequently, switching converters are usually more
efficient than linear converters because their components spend less time in
linear operating regions.
Some DC power supplies use AC mains electrically as an energy
source. Such power supplies will sometimes employ a transformer to
convert the input voltage to a higher or lower AC voltage. A rectifier is use
to convert the transformer output voltage to a varying DC voltage, which in
turn is passed trough an electronic filter to convert in to an unregulated DC
voltage. The filter removes most, but not all of the AC voltages variation, the
remanning voltage variation is known as ripple.

LIGHT EMITTING DIODE (LED):

A light emitting diode (LED) is a two lead semiconductor light source.
It is a PN junction diode, which emits the light when it is activated. When
suitable voltage is applied to the leads, electrodes are able to recombine with
electron holes within the device, releasing energy in the form of photons.
27

This effect is called electroluminescence, and the colour of the light

(corresponding to the energy of photons) is by determined by energy band
gap of the semiconductor.
An LED is often small in area and integrated optical component is
used to shape its radiation pattern. Appearing as practical electronic
component in 1962 the earliest LED emitted low intensity infrared light.
Infrared LED are still frequently used as transmitting elements in remote
control circuit, such as those in remote controls for a wide variety of
consumer electronics. The first visible light LED wee also of low intensity
and infrared wavelengths with very high brightness.
Early LED was often used as indicator lamps for electronics device,
replacing small incandescent bulbs. They were soon packaged into numeric
readouts in the form of seven segment displays and were commonly seen in
digital clocks.

FIG.13: LIGHT EMITING DIODE

FIG.14: CONSTRUCTION

Recent development in LED permits them to be used in environment

and task lighting. LED has much advantage over incandescent light sources
including lower energy consumption, longer lifetime, and improved physical
robustness, smaller size and faster switching. Light emitting diodes are now
like aviation, lighting, automotive, headlamps, advertising, general limiting,
traffic signals, and camera flashes. However, LED powerful enough for
28

room lighting are still relatively expensive, and require more precise current
and require more precise current and heat management than compact
florescent lamp sources of comparable output.
The LED consists of a chip of semi conducting material doped with
impurities to create PN junction. Current flow easily from p side to n side
but not in reverse direction. Charge carriers electron and holes flow into the
junction from electrode with different voltages. When electrons meet to hole,
it falls into the low energy level and release energy in the form of a photon.
Its colour depends on the band gap energy of a material forming PN
junction.
LED has allowed new text, video displays, and sensors to be
developed, while their high switching rates are also useful in advanced
communications technology.

CHAPTER

4
29

ESTIMATING
AND
COASTING

ESTIMATING COASTING

S. No.

Components

Specification

Quantity

Cost/Component
(Rs)

Total Cost
(Rs)

30

1.

Power
Supply

6v

40

40

2.

DC motor

6v

35

35

3.

Resistor

10 ohm

2.5

10

4.

Resistor

1 kilo-ohm

10

5.

Resistor

1 ohm

6.

Thermistors

470 ohm

10

80

7.

Diode

IN 4007

Total cost of the component

= Rs.

183

31

CHAPTER

RESULT AND
APPLICATION

In this project we use NTC thermistor for control the speed of motor,
NTC thermistor is temperature sensor. The voltage reading of the fan is
about 5 volt. It senses the temperature automatically and controls the speed
of dc motor. This technique is used mostly in computers etc.
A large number of motor are being used in a general purposes in our
surrounding from house hold equipment to industries. In many places
controlled motor is used. The speed control of motor is uses in industries,
transmitting mechanical power, robots and computer etc.
32

33

CHAPTER

BIBLIOGRAPHY

FIG.16: BIBLIOGRAPHY

www.ebookbrowse.com
www.electronicsforyou.com
www.digitek.in
www.sridigitek.com
www.electronicsforyou.com

34

APPENDIX

SOLDERING
TECHNIQUE

FIG: 17 SOLDERING

SOLDERING
Soldering is a process in which two or more metal items are joined
together by melting and flowing a filler metal (solder) into the joint, the
filler metal having a lower melting point than the adjoining metal. Soldering
35

differs from welding in that soldering does not involve melting the work
pieces. In brazing, the filler metal melts at a higher temperature, but the
work piece metal does not melt. In the past, nearly all solders contained lead,
but environmental concerns have increasingly dictated use of lead-free
alloys for electronics and plumbing purposes.

BASICS
Step 4

Carefully wipe the tip on the damp sponge until clean. Continually wipe the
tip while soldering a circuit board.

Step 5

Bend the lead of component using fine pliers so that it easily slides into the
holes of the print circuit pad.

Step 6

Insert the component to be soldered into the circuit board and bend the leads
protruding from the bottom of the circuit board at an angle of approx 45.

Step7

Cut the leads of the component close to the outer edge of the solder pad.

Step 8

Keep the soldering iron tip still while moving the solder around the joint as
it melts.

Step 9

Remove the solder tip first and the solder wire next, (prevents spiking).

OLDERING PROCEDURE:
Step 1

Check that your soldering iron tips is suitable for the project. (no larger than
the diameter of the pas). Check the tip is clean and shiny. If not, tin it by
adding a small amount of solder to the tip.

Step 2

Adjust the temperature of the soldering station to 350 C (degrees Celsius).

Step 3

Ensure the solder sponge is damp. A dry sponge will not clean the tip
effectively, and one that is too wet will lower the temperature of the tip
making for an ineffective solder joint.

36

Step 10 Allow to the joint to cool naturally and undisturbed, do not blow on the solder
joint to cool it.
Step 11 When you have completed all solder joints thoroughly clean your board, using
Isopropyl Alcohol, and a bristle brush, to remove the flux residue and other
contaminants.
Step 12 Wipe or pat dry with a lint free tissue to remove traces of residue.
Step 13

Step 13

Inspect for a good solder connection. The solder joint should be clean,
Smooth and shiny.

Leave a large blob of solder on the tip when switching the iron off as this
will protect the tip from oxidation and contamination.

37

Soldering Safety Precautions:

1. Only work in an environment that is well lit and ventilated.
2. Always unplug the soldering iron when it is unattended.
3. Be careful to keep clothes, hair, power cables and skin etc away from iron tip and
the metal shaft because it be burn.
4. Be careful when returning iron to it stand, make sure it is secure an off.
5. Always handle the iron by the plastic handle.
6. Point circuit away from self and others whilst trimming down component and be
careful of any sharp bits of metal whilst handling circuit or component.

38