REPORT ON TEMPERATURE CONTROLLED FAN REGULATOR

(Innovation Product)

By, SANI DAHIRU BUBA

GS 34084

Course Code: EAS5101 Course Title: INNOVATION STUDIES 1 Lecturer: Dr. AZMIN SHAKRINE MOHD RAFIE

1.0 Introduction Ventilation generally falls within the domain of another branch of Engineering commonly referred to as HVAC. A heating system (H in HVAC) is designed to add thermal energy to a space or building in order to maintain some selected air temperature that would otherwise not be achieved due to heat flows (heat loss) to the exterior environment. The heating system is accomplished using central heating system or portable electric heaters or traditionally by burning coal in a fireplace which is mostly applicable to temperate climates. A ventilating system (V) is intended to introduce air to or remove air from a space, that is, to move air without changing its temperature. Ventilating systems may be used to improve indoor air quality or to improve thermal comfort. Ventilating systems are accomplished using fans of various sizes and arrangements depending on the need or traditionally using hand fan. A cooling system ("C" which is not explicitly included in the HVAC acronym) is designed to remove thermal energy from a space or building to maintain some selected air temperature that would otherwise not be achieved due to heat flows (heat gain) from interior heat sources and the exterior environment. Cooling systems are normally considered as part of the AC in HVAC; AC stands for airconditioning [1]. HVAC is one of the largest consumers of energy in residential, public, commercial and the hospitality industry, constituting approximately 30 percent or more of total costs. HVAC systems that operate properly are essential in lodging facilities and contribute to employee productivity and guest satisfaction. A ventilation system was defined in [2] is a system which circulates fresh air throughout a confined space or spaces, while removing contaminated or stale air. Ventilation systems are used in various settings, including homes and workplaces. Some of the application of these systems may include maintaining a constant humidity and temperature, getting rid of dust and allergens from the air and providing the proper exchange of oxygen and carbon dioxide levels. There are various types of ventilation systems, which are typically classified as natural or mechanical systems. A natural ventilation system relies on atmospheric conditions, while a mechanical system is a man-made device that assists in the filtration and circulation of the air. The most common form of a natural system consists of an outlet on the roof and openings throughout the lower part of a building. This allows air to rise and exit through the roof, and new air to enter from below, providing constant circulation. Mechanical ventilation systems actively pull fresh air in and push stale air out. They may have other capabilities, including heating and 2

cooling, and require some form of energy to operate. One common form of mechanical ventilation system is the heating, ventilating, and air conditioning (HVAC) units which are used in homes and other buildings. Advanced ventilation systems are used within certain industries as a safety measure. This kind of mechanical ventilation system may be required by law, depending on the industry. They are often required in mining, underwater, and majority of manufacturing industries. The exact type of advanced mechanical ventilation system used will ultimately depend on the individual needs of the company and any applicable laws. Some of these industries may have to comply with stipulated air quality guidelines regarding requirements of such equipment. This may be dependent upon the geographical location of the particular facility. The main purpose of ventilation systems in such settings is to filter harmful substances from the air, provide a constant supply of oxygen, and maintain a healthy atmosphere for breathing. A ventilation system can be used in conjunction with other equipment to establish desirable temperatures and to maximize the air circulation. It is not uncommon for large buildings and warehouses, kitchens and washrooms to be equipped with exhaust fans that assist in bringing in fresh air in while pushing the stale air out. These fans may be placed at various ventilation openings throughout the building or on the roof. A ventilation system with exhaust fans are often used in buildings that generate substantial amounts of heat or contain fumes [3]. Some exhaust fans operate continuously and many operate when not necessary. When building codes and standards permit, it is important to turn exhaust fans off when they are not serving a useful purpose. There may be opportunities to more efficiently control exhaust fans in areas such as restrooms, locker rooms, showers, gymnasiums, laboratories, custodial closets, dedicated copy rooms, laundry rooms, food preparation spaces, and other locations. Better control of exhaust fans not only saves the electricity required to operate the fan but also the cost of conditioned air that is exhausted unnecessarily. In the case of restrooms, exhaust fans can be rewired so that fans operate only when restroom lights are switched on. Even if fans are best left on when a building is occupied, at least savings are realized during unoccupied hours. Another option is to install occupancy sensors to control both the exhaust fan and lighting circuits. A wide variety of manual, electronic and programmable timers are also available for use where fan operations are related to the scheduled use of a space. In facilities where building automation systems (BAS) are utilized, exhaust fans can be controlled directly through the BAS 3

and set for scheduled occupancy use. In the case of gymnasiums, it is often preferable to control exhaust fans with a thermostat when exhausted and makeup air are used primarily to maintain the most comfortable conditions possible during the summer months. Behavior awareness is always a good starting place to encourage building occupants to keep exhaust fan and lighting circuits off when not in use [4].
1.2 Problem statement

Occupants of residential and commercial premises where fans are installed experience a lot of fatigue and inconvenience while changing the speed of fan manually as the room temperature changes. It is even a more difficult task for children and the elderly. Also, considering Malaysia as a tropical country, temperature changes are very drastic especially during the monsoon rains. Fan speed set at high speed in the morning hours due to heat will waste a lot of energy in the afternoon after rainfall when the temperature becomes low and the fan is still set at high speed. Therefore, a strong justification is made by designing a temperature controlled fan regulator whose speed is automatically regulated according to the ambient temperature.

1.3 Objectives The main objective of this work is to design and implement a Temperature controlled fan regulator to satisfy the problem statement. This will be achieved by addressing these specific objectives; 1. Obtain a suitable circuit diagram and adapt to local requirements. 2. Produce a printed circuit board and implement the design.

Figure 1 Typical fans used in homes and workplaces and accessories 5

1.4 Significance

The temperature controlled fan regulator is significant because; 1. It would be cheaper than the conventional fan regulator when mass produced. 2. It would save electrical energy by automatically adjusting current flow when the ambient temperature reduces so that the fan rotates slowly and thus consume less energy. 3. It will be more durable than the conventional fan regulator as there are no moving parts. 4. It will be easy to operate, once switched ON, it is self-regulating depending on the prevailing ambient temperature. 5. It provides a cheap and robust method of fan speed control when compared to the other products reported in the literature review.

2.0 Literature Review

]

Zulkifli [5] reported the design of an automatic room temperature control incorporating a security system using PIC16F876A microcontroller which drives a power transistor (BD135) and hence drive a brushless DC fan, LEDs and buzzer when the temperature varies above or below certain temperatures ranges. The value of the temperature is displayed on an LCD screen. The circuit uses two temperature sensors placed at different locations for the purpose of monitoring the temperature. The system operates in three different conditions depending on the range of temperature. If the current value of temperature is higher than desired value, the fan will start functioning and LED will indicator high temperature. On The other hand, if the temperature increases and reaches a desired value, the fan will stop functioning and LED will indicate normal stat. Finally, if the current temperature is lower than the desired value, fan will not function and LED will indicate low temperature. Any changes in temperature in the room is continuously monitored and displayed on the LCD. In addition the LEDs are used to indicate the current state and range of temperature in the server room. The project is basically aimed at monitoring the room temperature and tries to minimize it when it reaches a certain preset value. It differs slightly from the project under consideration although the applications are similar. Furthermore,

the project is very expensive because of the cost of microcontroller and also requires and external DC power supply. Alvasim et al. [6] reported the design of a remote controlled fan regulator where the speed of a fan is controlled by using a remote switch similar to the DVD remote switch. The variation in the firing angle of Triac is used for regulating the fan speed. Any button on the remote can be used for controlling the speed of the fan. Using the remote switch, the speed of the fan can be regulated while sitting on the couch or bed and has five variable speeds. This project shares a certain similarity with the current study in that both regulate the speed of a fan. However, it is more expensive than the product considered in this study because of the use of infra-red sender and receiver. Nazar [7] reported the design and construction of an automatic control room temperature using PIC with LCD display. The product operates automatically based on the changes of room temperature. For the detection of room temperature, a temperature sensor (LM35DZ) is used to send signal to microcontroller (PIC16F876A) which decides to increase or decrease the speed of the fan based on the received signal from temperature sensor. This product is also expensive because of the PIC controller and will require a separate power supply but it is also a selfregulating system once switched on. Abd. Ghani [8] also reported the design of a microcontroller based smart fan system. The electric fan automatically switches the speed according to the environmental temperature changes. The system consists of a combination of sensor, controller, driver and motor with integration of embedded controlled programming by means of MC68HC11A1 as the main controller. Norazmi [9] reported the design of temperature control system for a server room. The system consists of temperature sensor, PIC, LCD, driver circuits, AC air heater and AC motor. Three drivers are used for triggering process to switch on the AC heater and another two are for triggering levels of the motor. The motor operates on the basis of two temperature ranges, meaning it has two levels of speed. The function of this system is for controlling the internal temperature of a regular room automatically. It will operate based on the values or ranges of temperature in the room which is detected by the temperature sensor. If the temperature in the first range (0C to15C), the air heater will operate to heat the server room which in very cold temperature. If it is in the second range (16C to 25C) the system will not be enabled because its achieving normal temperature range. If temperature is in the range26C to 40C, the motor 7

will be triggered for level 1 to decrease the temperature value. If it is more than 40C, the motor will be triggered for level 2 and its speed becomes faster at this level. Both output devices are considered important to maintain a constant temperature in the room. This system can be categorized as an automatic system. In summary, from the previous work reviewed, it was found that most of the works except one centered on control of room temperature, whereas this study is concerned with the regulating the speed of fan based on temperature. The applications are quiet similar, but they have a disadvantage of cost and also the products need an external power supply to operate unlike the proposed temperature controlled fan regulator which uses AC supply and also is much cheaper.

3.0 Methodology

The temperature controlled fan regulator (TCFR) would be implemented in the following simple steps; 1. The basic circuit was sourced from the internet. 2. The circuit was adapted for 240V, 50Hz supply system suitable for use in Malaysia. 3. The modified circuit diagram was redrawn using ISIS Professional Software. 4. The printed circuit board (PCB) was produced and the circuit was constructed. 5. The product was tested and packaged.

3.1 Circuit description

The main component in the circuit diagram of Figure 1 is the Triac. It is an electronic component approximately equivalent to two silicon-controlled rectifiers (SCRs/Thyristor) connected in inverse parallel (paralleled but with the polarity reversed) and with their gates connected together. The formal name for a Triac is bidirectional triode Thyristor resulting in a bidirectional electronic switch which can conduct current in either direction when it is triggered (turned on) and thus doesn't have any polarity. It is triggered by applying either a positive or a negative voltage to its gate electrode (with respect to A1, otherwise known as MT1). Once triggered, the

device continues to conduct until the current through it drops below a certain threshold value known as the holding current, such as at the end of a half-cycle of alternating current (AC) mains power. In addition, applying a trigger pulse at a controllable point in an AC cycle allows the control of the percentage of current that flows through the Triac to the load (phase control). The Triac used in this circuit is BT136. It is Thyristor with a firing angle nearly 450. A snubber circuit consisting of a resistor and capacitor is used to control the firing angle of Triac. This firing angle determines the speed of the fan.

3.2 Principle of operation

This fan regulator circuit will automatically control the speed of the fan according to the temperature. Two thermistors (R1 and R2) are used as the temperature sensors. When the temperature is increasing, the resistance of R1 which is a thermistor with negative temperature coefficient (NTC) decreases and at the same time the resistance of R2, a thermistor with positive temperature coefficient (PTC) increases. The rate of change of the resistance will be different for R1 and R2. When the resistance is varied the firing angle of the Triac changes and so do the speed of the fan.

Figure 2, Basic circuit diagram of a temperature controlled fan regulator 9

3.3 Design Analysis

In Malaysia, the single phase supply is rated at 240V, 50Hz. According to a study conducted in [10], a ceiling fan operated on slow, medium and high speeds consumed 53, 66 and 73 watts respectively. Therefore, an average of the three fans power consumption of 64 watts has been considered as the power rating of the fan in this design. Since the voltage and power are known, the current taken by the fan can be calculated from Ohms law in equation 1.
I P V

(1)

64 0.27 A 240

According to IEE wiring regulations, a lighting sub-circuit should be protected by a 5A fuse, therefore a fan fitting is considered as a lighting point in this case, hence the use of 5A fuse in series with the switch in Figure 3. The inductor L1 is in series with the fan, therefore a current of 0.27A would pass through the inductor which can handle it safely. Capacitors are voltage controlled elements, they were selected based on the circuit voltage of 240V and hence each is capable of handling this voltage safely. The Triac and Diac were selected based on their current capacity which is about 4A, this value is much higher than the current flowing through the circuit, i.e. 0.27A. The voltage appearing across R1, R2 and R3 can be found from potential divider principle as in equation 2.
V R1 Vs R1 R1 RT

(2)

Where RT

R 2 R3 R 2 R3
5k 6.8k 2.9k 5k 6.8k

(3)

From equation 3, RT Therefore VR1 240

VR 2 240

100k 233V 100k 2.9k

5k 152V 5k 2.9k

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Because R2 and R3 in parallel, the voltage drop across them is slightly less than that across R1 which is usual.

3.4 Summary of Components I. II. III. IV. V. VI. VII. VIII. The circuit can be assembled on a Vero board. L1 is a70uH inductor. C1 and C2 are polarized Capacitors and must be rated at least 250V. C3 is also a polarized Capacitor must be rated at least 600V. BT136 is a Triac which must be able to handle about 4A load current. F1 should be a 5A fuse for mains protection. BD2 is a Diac which provides the Triac with triggering pulses of square shape. R1 and R2 are thermistors (temperature sensors) while R3 is a normal Resistor.

Figure 3, Customized circuit diagram of TCFR 240V, 50Hz operation

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3.5 Package Sample

Figure 4 Showing a knock out box and a switch for packaging the TCFR after construction

3.6 Unit cost of TCFR

S/N Description of item 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Inductor (L1) NTC thermistor (R1) PTC thermistor (R2) Capacitor (C1, C2, C3) Resistor (R3) Triac BT 136 Diac DB2 Production of PCB PVC knock out box

Unit price (RM) Quantity Amount (RM) 6.25 0.91 4.97 0.46 0.95 3.60 2.50 25.00 0.5 1 1 1 3 1 1 1 1 1 1 ----6.25 0.91 4.97 1.38 0.95 3.60 2.50 25.00 0.5 1.00 46.97

1-way double pole switch 1.00 Total ------

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After producing the PCB, the TCFR is mounted on a PVC or metallic knockout box which will be covered with the double pole one-way switch. This may be installed on the wall surface or mounted flush (wall recessed). However, for best performance, it is recommended to be surface mounted so as to enable best performance of the temperature sensors. The cost of one unit of the TCFR is approximately RM 47.00. However the cost can be reduced to almost 50% when mass produced as the cost of electronic components is much cheaper when purchased in bulk. The TCFR can compete favorably with the conventional fan regulator which costs about RM 30.00.

3.7 Application of TCFR to Innovation Studies

I.

The TCR is an innovation product as it provides a better way to solve a problem (electrical energy saving, eases operation of fan, less fatigue and convenient).

II. III.

The TCR introduces entrepreneurship as it can be mass produced and marketed. Society will benefit from it. 3.7.1 Area of Invention The area of invention is Home and Office; appliance and comfort. 3.7.2 Kind of Invention Labour saving; no need for manual changing/selection of fan speed, no fatigue and inconvenience of leaving the bed of sofa/couch to change speed of fan. 3.7.3 General concept Feedback principle; change in temperature causes change in resistance which in turn changes the firing angle of a Triac to allow more or less current to flow and hence controls the speed of the fan.

4.0 Conclusion

The design and construction of a temperature controlled fan regulator has been presented. The TCR would adequately replace the existing conventional fan regulator for speed control of fans. The TCR can be used to control the speed of ceiling fans, kitchen and bathroom exhaust fans and wall mounted fans. By making the unit much smaller, it may be used to control the speed of 13

standing and table fans also. Therefore, the aim of attending the Innovation Studies class has been achieved.

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References

[1] Walter Grondzik, Richard Furst, HVAC Components and Systems, Vital Signs Curriculum Materials Project. [2] http://www.wisegeek.com/what-is-a-ventilation-system.html. [4] Reznor, A., A Brief Explanation of ASHRAE Energy Efficiency and Ventilation Standards, White Paper. [3] Automatic Temperature Controlled Fan, Electronic Projects Vol. 19, P 189. [5] Ahmad Faris Bin Zulkifli, Automatic Room Temperature Control with Security System, B. Eng. Thesis, Universiti Malaysia Pahang, May, 2009. [6] Alvasim P. A., Anumol R., Geo J., Nimmy Y., Pradeep K. V., Remote Controlled Fan Regulator, B. Eng. Thesis, University of Calicut India, 2009. [7] Hafiz Bin Nazar, Automatic Control Room Temperature Using PIC with LCD Display, B. Eng. Thesis, Universiti Teknikal Malaysia Melaka, April 2009. [8] Muhammad Khairi Bin Abd. Ghani, Microcontroller Based Smart Fan System, B. Eng. Thesis, Universiti Malaysia Pahang, 2007. [9] Nor Mazlee Bin Norazmi, Temperature Control System, B. Eng. Thesis, Universiti Malaysia Pahang, May 2009. [10] http://www.rpc.com.au/information/faq/power-consumption/miscellaneous.html.

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