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Author Subject: Custom fan speed controller
owain

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Post #1
Right. Imagine I was ripping out the standard blower and bits to stick in proper in-line 12v fans instead. This is all fine.

However, when it comes to controlling the speed I'm not really sure what's best - back in t'day when I did my Electronics GCSE we only really dealt with low-current stuff, where you could use potentiometers and variable resistors to change the brightness/speed of a component.

However these fans draw about 3A, so nearly 50W of power - far more than you can push through a standard variable resistor.

So what can I do instead? Get a rotary switch and wire in a selection of big fat resistors or am I missing something obvious? All cars do this, so it can't be that expensive or difficult a thing to do. I'd keep the standard electrics but I want to pull all that stuff out and do it more neatly myself.

Can anyone with more knowledge of electronics lend me some ideas? Also I can't really remember how to calculate the resistances I'd need to run at two or three different speeds.

Anyone?

Ta people.

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Posted 31st Dec 2010 at 19:19
bobdylan_55

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Post #2
just have a switch, on or off Wink much easier and saves faffing about.

if you are sure u want to do it however you will be able to get high ampage variable resistors that work in the same way.

Alternatively have a toggle switch with like 4 positions and wire each position with a different voltage hence having 4 different speed settings.

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Posted 31st Dec 2010 at 19:29
owain

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Post #3
bobdylan_55 wrote:
just have a switch, on or off Wink much easier and saves faffing about


Thought of that, but on a hot day you'll want it on full, on a cold day you certainly won't.

bobdylan_55 wrote:
get high ampage variable resistors that work in the same way


Can't find any, without going for big comedy rheostat things that are about 4" across.

bobdylan_55 wrote:
have a toggle switch with like 4 positions and wire each position with a different voltage hence having 4 different speed settings


That's no different really to having a rotary switch, it's the changing of resistance that's the problem.,

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Posted 31st Dec 2010 at 19:33
welshpug!

Capt Pedantic

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Post #4
personally I'd just leave it as it is, the heater box inc fan only weighs 5 kilos, stop making more work for yourself and just get out there using it!

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Posted 31st Dec 2010 at 19:46
owain

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Post #5
Yeah tempting, but that just wouldn't be fiddling enough Smile

The little fans are about 300g each, so a fair bit of weight can be saved, especially if I want to rip out loads of the dashboard as well. Which obviously I do.

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Posted 31st Dec 2010 at 19:50
welshpug!

Capt Pedantic

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Post #6
fans are a fat lot of good without all the ducting that the heater box and dash carry Wink

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Posted 31st Dec 2010 at 20:03
owain

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Post #7
Yeah I'm working on that, flexible ducting and random fabricated brackets ftw!

I may end up just with the standard stuff, just feeling out the options atm.

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Posted 31st Dec 2010 at 20:06
cosmic spanner

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Post #8
It's been a few years since I last looked at an electronics textbook, but the way I'd do this is to use an oscillator (the mighty 555 timer LOL) to generate a square pulse which can vary between say 10% and 100% duty cycle and use this output to drive them. Potentiometer adjusts the oscillator rate (so pot can be nice & low current), use a MOSFET transistor to do the heavy lifting/high current switching.

It's the way LEDs are driven & dimmed - rather than varying the current, you vary the duty cycle so pulse on & off at whatever Hz (> human eye can see). Look up 12v dimmer circuits you'll get loads of ideas.

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Posted 31st Dec 2010 at 20:14
owain

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Post #9
On a motor?!

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Posted 31st Dec 2010 at 20:12
cosmic spanner

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Post #10
Yes, on a motor! As you've discovered for yourself, the 10A variable resistor is not an elegant solution, it's all about the duty cycles.

e.g. this

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Posted 31st Dec 2010 at 20:16
owain

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Post #11
Take your word, I'll probably stick to the resistors mind Wink

Oh man, I remember getting through thousands of those little 555's at school trying to make an LED flash. Good times...

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Posted 31st Dec 2010 at 20:15
cosmic spanner

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Post #12
In fact, if you scroll down on the above link even though it's titled LED dimmer they show it being used fo a 12V DC motor as well Wink

Now, how's your soldering (and do you still have your plywood LED flashing christmas tree to crib from)? Whistle

EDIT: or, solve the problem in the fans. Buy fan motors that have 3 windings to give 3 speeds (low med hi) and then a 3-way switch.

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Democracy is two wolves and a lamb voting on what to have for lunch..
..Liberty is a well-armed lamb contesting the vote.

Project é - my 306 project thread.
Posted 31st Dec 2010 at 20:25
owain

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Post #13
Hmm, that looks interesting enough. My soldering's pretty good, alas all the christmas trees are long gone now.

Pretty sure I've got a guitar distortion pedal made out of 9mm MDF knocking about still though.

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Posted 31st Dec 2010 at 20:24

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