CHAPTER ONE

TEMERATUE CONTROLLED FAN - AN OVERVIEW

1.1 INTRODUCTION
Over the last decade, advances in electronics have made devices smaller, cheaper and faster.
Their applications are also made easier for by adopting automation. Controlling of speed of
fan using the speed of a fan using temperature sensor is one of them. It is also a part of smart
home application where the fan will gradually increase its speed if the temperature is
increasing. In general, home appliance fans need to be operated manually with the help of
regulators with the variation of temperature, thus requires a repeatedly extra effort for
regulating the fan speed which acts to our agony.

1.2 WHAT IS AUTOMATION?

Automation can be defined as the technology by which a process or procedure is performed
without human assistance. In other words, Automation or automatic control is the use of
various control systems for operating equipment such as machinery, processes in factories,
boilers and heat treating ovens, switching on telephone networks, steering and stabilization of
ships, aircraft and other applications and vehicles with minimal or reduced human
intervention. Some processes have been completely automated.
Automation has been achieved by various means including mechanical, hydraulic, pneumatic,
electrical, electronic devices and computers, usually in combination. Complicated systems,
such as modern factories, airplanes and ships typically use all these combined techniques.
The benefit of automation includes labor savings, savings in electricity costs, savings in
material costs, and improvements to quality, accuracy and precision.

1.3 TEMPERATURE CONTROLLED AUTOMATED FAN

In temperature controlled fan the working is based on heating the sensor, i.e. the thermistor,
where the speed of the fan is dependent and controlled by any device’s temperature like PC.
As the temperature of the device increases or decreases, the speed of fan increases or
decreases respectively. So it can be used mainly as a cooling device. By modifying the circuit
slightly, it can also be used to control the room temperature, depending on the property of
thermistor. The thermistor decreases its resistance with increasing temperature; hence the
electrical conductivity also increases, increasing voltage across it, resulting in an increment in
the speed of the fan. Thus, it is possible to control the speed of the fan automatically when the
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device’s temperature varies. Experiment can be followed to evaluate whether this circuit can
save energy through the use of temperature sensor and thus promote efficiency.
Overall, the general public does not want to manually change the fan speed with the change
in temperature. The temperature controlled DC fan is meant to address this issue. It
automatically switches on/off the fan as change in temperature is observed by sensors. It can
be used or in smart homes, smart cities. It will also save the electricity and power
consumption. It is mentioned in many articles that billions of KW-hrs of energy per year is
used by fans and this constitutes of 15% of power consumption. So it becomes necessary to
reduce the power consumption by automatically controlling the speed and power consumed
on the basis of temperature. Microcontroller can be used to control the speed by measuring
or evaluating the changes in temperature.

1.4 BENEFITS OF AUTOMATINC FAN CONTROL

No control adjustments
With automated fan control, you no longer need to disrupt your workflow to adjust the speed
and direction of your fans. Although it only takes a few moments to adjust the fan, waiting
for your body to recognize thermal discomfort allows the environment to swing into an
uncomfortable climate. Automating the fans saves time and maintains a consistently
comfortable environment.

Optimized fan performance

Identifying the best speed and direction to operate your fans can be difficult, especially
during the spring and fall seasons when the temperatures frequently fluctuate. The
automation software calculates all of this for you and perfectly optimizes your fans’
performance for the current climate.

Savings on heating and cooling

If you couple your fans with air conditioning, the cooling effect created by the fans will
enable you to set your thermostat higher while maintaining the same level of comfort. In the
winter, the fans run in reverse to mix the heated air, eliminating hot and cold spots and
decreasing your heating costs. Automation maximizes energy efficiency across your climate
control solutions.

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Easy installation
It is easy to handle and economical. For cooling heat dissipating devices, installation is easy.

1.5 APPLICATIONS OF AUTOMATED FAN CONTROL

• Cooling fans for laptops and computers.
• Used for cooling the car engine.
• Cooling fans are an important part of thermal management for high-power chips (such as
CPUs, FPGAs, and GPUs) and systems.
• Temperature Controlled Fan can be used to control the temperature of devices, rooms,
electronic components etc. by monitoring the temperature.

1.6 HOW AUTOMATED FAN CONTROL WORKS

Automated fan control measures temperature. This information is used to calculate the heat
index which captures the “feels like” temperature rather than just the actual temperature.
Based on the heat index, the automated fan control software identifies the best operating
speed and direction and runs the fans accordingly.

Using the automated fan control is as simple as selecting a desired temperature range and
leaving it to do its work. When the temperature rises above the desired temperature range, the
fans will automatically run in the forward direction and create a cooling effect. If the
temperature drops below the desired temperature range, the automated fan control will run
the fans in the reverse direction to redistribute the warm air overhead and eliminate hot and
cold spots without generating a discernible breeze.

1.7 NEED OF AUTOMATION OF FAN

Electric fan is one of the most popular electrical devices due to its cost effectiveness and low
power consumption advantages. It is a common circuit and widely used in many applications.
It is also one of the most sensible solutions to offer a comfortable and energy efficient. In
fact, the fan has been long used and still available in the market. Fan can be controlled
manually by pressing on the switch button. Where in this method, any change in the
temperature will not give any change in the fan speed. Except the usage change the speed of
the fan which is manually. So, an automatic temperature control system technology is needed
for the controlling purpose in the fan speed according to the temperature changes which can
be used in various applications.
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1.8 DIFFERENT TECHNIQUES OF FAN AUTOMATION
Here we describe different techniques used for automatically controlling a cooling fan's speed
in a particular application like

Cheap heat controlling

High-speed chips tend to run hot. As they get faster, they get hotter. New generation high-
speed digital chips use smaller processes that allow the supply voltage to be reduced, which
helps somewhat, but the number of transistors increases faster than the supply voltage
decreases. Power levels, therefore, continue to rise. As chip temperature increases,
performance can suffer. Parameters shift, maximum operating frequencies decrease, and
timing can fall out of specification. From the user's point of view, the product is no longer
operating properly when this occurs. The first reason for cooling high-speed chips, therefore,
is to maintain good performance for the longest possible operating time and over the widest
possible range of environmental conditions. The maximum allowable temperature for a high-
speed chip to meet its parametric specifications depends on the process and how the chip is
designed (how "close to the edge" the chip is operating), among other factors. Typical
maximum die temperature values range from +90°C to +130°C. Beyond the point where
performance degradation begins, excessive die temperature causes catastrophic damage to
chips. The maximum die temperature limit is usually well over +120°C and depends on such
factors as process, package, and duration of high-temperature conditions. High-speed chips
are, therefore, cooled to avoid reaching a temperature that could both degrade performance
and cause irreparable damage.
A single cooling technique is rarely used with high-speed chips. Instead, combinations of
techniques are generally necessary to ensure high performance and continued reliability. Heat
sinks, heat pipes, fans, and clock throttling are commonly employed to cool high-speed chips.

Temperature controlled fan, can help solve the heat problem, but introduce problems of their
own. Fans can dramatically reduce the temperature of a high-speed chip, but they also
generate a great deal of acoustic noise. The noise from a full-speed cooling fan is annoying to
some consumers and is also becoming a target of government agencies concerned about the
long-term effects of noise in the workplace. Fan noise can be reduced significantly by

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varying the fan's speed based on temperature; the fan can turn slowly (and very quietly) when
temperature is low, and can speed up as temperature increases.

Regulating the Power-Supply Voltage of the Fan

The need for fan control forces the designer to make several key choices. The first choice is
the method of adjusting the fan's speed. A common method of adjusting the speed of a
brushless DC fan is to regulate the power-supply voltage of the fan. This approach works
well for power-supply voltages as low as about 40% of the nominal value.

Powering the Fan with A Low-Frequency PWM Signal

Another popular fan-speed control technique is to power the fan with a low-frequency PWM
signal, usually in the range of about 30Hz, whose duty cycle is varied to adjust the fan's
speed. This is inexpensive because a single, small pass transistor can be used. It is efficient
because the pass transistor is used as a switch. A disadvantage of this approach, however, is
that it can make the fan somewhat noisier because of the pulsed nature of the power supply.
The PWM waveform's fast edges cause the fan's mechanical structure to move (somewhat
like a badly designed loudspeaker), which can easily be audible.

Using Fans with Speed-Control Inputs

A third approach can be used with fans that have speed-control inputs. Such fans, usually
referred to as "four-wire" fans (ground, power, tachometer output, PWM speed-control
input), allow a logic-level PWM signal to control their speed. This PWM signal is usually in
the 20kHz to 50kHz range, and the resulting fan speed is roughly proportional to the duty
cycle.
Another fan-control design choice is whether the fan's speed is measured as part of the
control scheme. In addition to power and ground, many fans are available with a third wire
that provides a "tachometer" signal to the fan-control circuitry. The tachometer output
produces a specified number of pulses (two pulses, for example) for each revolution of the
fan. Some fan-control circuits use this tachometer waveform as a feedback signal that allows
the fan's voltage or PWM duty cycle to be adjusted to give a desired RPM. A simpler
approach ignores any tachometer signal and simply adjusts the fan's drive to speed up or slow
down with no speed feedback. Speed control using this method is less precise, but cost is
lower and at least one feedback loop is removed, simplifying the control system.
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In some systems, it is important to limit the change rate of the fan speed. This is most critical
when the system is in close proximity to users. Simply switching a fan on and off or changing
speed immediately as temperature changes is acceptable in some environments. When users
are nearby, however, sudden changes in fan noise are apparent and annoying. Limiting the
rate of change of the fan's drive signal to an acceptable value (e.g., 1% per second) ensures
that the acoustic effects of fan control are minimized. The fan speed still changes, but it does
so without attracting attention.

Implementing fan-control circuitry can be done in several ways. A variety of remote

temperature sensors with up to five sensing channels is available that can detect the die
temperature of the high-speed chip and transmit temperature data to a microcontroller. Fan-
speed regulators with multiple channels of fan tachometer monitoring can provide reliable
control of fan RPM or supply voltage based on commands from an external microcontroller.
For low cost and simple implementation, ICs are available with temperature sensing and
automatic fan control included in a single package. Sensor/controllers also normally include
over temperature detection for clock throttling and system shutdown, thereby protecting the
high-speed chips from catastrophic failure due to overheating.

In this chapter we have discussed about the details of temperature controlled fan. In next
chapter we will focus on the components that are used in temperature controlled fan used in
industry. The discussion will also cover the block diagram related to the topic.

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 CHAPTER TWO
TECHNOLOGY USED
2.1 INTRODUCTION
All computing systems other than general purpose computer (with monitor, keyboard, etc.)
are embedded systems.
Embedded system is a way of working, organizing or performing one or many tasks
according to a fixed set of rules, program or plan. In other words, an arrangement in which all
units assemble and work together according to a program or plan. An embedded system is a
system that has software embedded into hardware, which makes a system dedicated for an
application (s) or specific part of an application or product or part of a larger system. It
processes a fixed set of pre-programmed instructions to control electromechanical equipment
which may be part of an even larger system for organizing an embedded system,
microcontrollers are the most essential elements.

2.2 BLOCK DIAGRAM

The block diagram for the circuit is shown in Fig. 2.1.

POWER SUPPLY

RELAY
RELAY FAN
Sensor (LM35)

DRIVER
Temperature

ARDUINO
PRO MINI

BUZZER
&
INDICATOR

LCD

Fig. 2.1 Block Diagram

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2.3 COMPONENT LIST
Here we explain the components used to design the whole system with detailed
specifications. Technology used and particulars are also given regarding each of the
components.
The hardware developed for the present system consists of the following main modules and
circuitry:
➢ Arduino Pro Mini microcontroller board
➢ Temperature sensor (LM35)
➢ LCD
➢ Relay driver
➢ Relay
➢ Passive components
➢ Power supply
➢ Buzzer
➢ Transistor

2.4 ARDUINO PRO MINI MICROCONTROLLER BOARD

The Arduino Pro Mini is a microcontroller board based on the ATmega328. It has 14 digital
input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, an on-board
resonator, a reset button, and holes for mounting pin headers as shown in Fig 2.2. A six pin
header can be connected to an FTDI cable or Sparkfun breakout board to provide USB power
and communication to the board.

Fig. 2.2 Arduino Pro Mini

The Arduino Pro Mini is intended for semi-permanent installation in objects or exhibitions.
The board comes without pre-mounted headers, allowing the use of various types of
connectors or direct soldering of wires. The pin layout is compatible with the Arduino Mini.

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There are two version of the Pro Mini. One runs at 3.3V and 8 MHz, the other at 5V and 16
MHz.

2.4.1 Technical Features

Table 2.1 shows the technical features of Arduino Pro Mini Board.

Table 2.1 Technical Features of Arduino Pro Mini Board

Microcontroller ATmega328
Operating Voltage 3.3V or 5V (depending on model)
Input Voltage 3.35 -12 V (3.3V model) or 5 - 12 V (5V model)
Digital I/O Pins 14 (of which 6 provide PWM output)
Analog Input Pins 6
DC Current per I/O Pin 40 mA
Flash Memory 32 kB (of which 0.5 kB used by bootloader)
SRAM 2 kB
EEPROM 1 kB
Clock Speed 8 MHz (3.3V model) or 16 MHz (5V model)

2.4.2 Power

The Arduino Pro Mini can be powered with an FTDI cable or breakout board connected to its
six pin header, or with a regulated 3.3V or 5V supply (depending on the model) on the Vcc
pin. There is a voltage regulator on board so it can accept voltage up to 12VDC. If you're
supplying unregulated power to the board, be sure to connect to the "RAW" pin on not VCC.

The power pins are as follows:

• RAW. For supplying a raw voltage to the board.

• VCC. The regulated 3.3 or 5 volt supply.
• GND. Ground pins.

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2.4.3 Memory

The ATmega328 has 32kB of flash memory for storing code (of which 0.5kB is used for the
boot loader). It has 2kB of SRAM and 1kBs of EEPROM (which can be read and written
with the EEPROM library).

2.4.4 Input and Output

Each of the 14 digital pins on the Pro Mini can be used as an input or output, using
pinMode(), digitalWrite(), and digitalRead() functions. They operate at 3.3 or 5 volts
(depending on the model). Each pin can provide or receive a maximum of 40 mA and has an
internal pull-up resistor (disconnected by default) of 20-50 kΩ. In addition, some pins have
specialized functions:

• Serial: 0 (RX) and 1 (TX). Used to receive (RX) and transmit (TX) TTL serial data.
These pins are connected to the TX-0 and RX-1 pins of the six pin header.
• External Interrupts: 2 and 3. These pins can be configured to trigger an interrupt on a
low value, a rising or falling edge, or a change in value. See the attach Interrupt() function
for details.
• PWM: 3, 5, 6, 9, 10, and 11. Provide 8-bit PWM output with the analog Write()
function.
• SPI: 10 (SS), 11 (MOSI), 12 (MISO), 13 (SCK). These pins support SPI
communication, which, although provided by the underlying hardware, is not currently
included in the Arduino language.
• LED: 13. There is a built-in LED connected to digital pin 13. When the pin is HIGH
value, the LED is on, when the pin is LOW, it's off.

The Pro Mini has 8 analog inputs, each of which provide 10 bits of resolution (i.e. 1024
different values). Four of them are on the headers on the edge of the board; two (inputs 4 and
5) on holes in the interior of the board. The analog inputs measure from ground to VCC.
Additionally, some pins have specialized functionality:

• I2C: A4 (SDA) and A5 (SCL). Support I2C (TWI) communication using the Wire
library.

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There is another pin on the board:

• Reset. Bring this line LOW to reset the microcontroller. Typically used to add a reset
button to shields which block the one on the board.

2.4.5 Communication

The Arduino Pro Mini has a number of facilities for communicating with a computer, another
Arduino, or other microcontrollers. The ATmega328 provides UART TTL serial
communication, which is available on digital pins 0 (RX) and 1 (TX). The Arduino software
includes a serial monitor which allows simple textual data to be sent to and from the Arduino
board via a USB connection.

A software serial library allows for serial communication on any of the Pro Mini's digital
pins. The ATmega328 also supports I2C (TWI) and SPI communication. The Arduino
software includes a Wire library to simplify use of the I2C bus; see the reference for details.
To use the SPI communication, please see the ATmega328 datasheet.

2.4.6 Programming

The Arduino Pro Mini can be programmed with the Arduino software (download). For
details, see the reference and tutorials.

The ATmega328 on the Arduino Pro Mini comes pre burned with a boot loader that allows
you to upload new code to it without the use of an external hardware programmer. It
communicates using the original STK500 protocol (reference, C header files).

2.5 TEMPERATURE SENSOR (LM35)

The LM35 series are precision integrated-circuit temperature sensors, whose output voltage is
linearly proportional to the Celsius (Centigrade) temperature. The LM35 thus has an
advantage over linear temperature sensors calibrated in Kelvin, as the user is not required to
subtract a large constant voltage from its output to obtain convenient Centigrade scaling. The
LM35 does not require any external calibration or trimming to provide typical accuracies of
±1⁄4˚C at room temperature and ±3⁄4˚C over a full −55 to +150˚C temperature range. Low
cost is assured by trimming and calibration at the wafer level. The LM35’s low output

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impedance, linear output, and precise inherent calibration make interfacing to readout or
control circuitry especially easy. It can be used with single power supplies, or with plus and
minus supplies. As it draws only 60 µA from its supply, it has very low self-heating, less than
0.1˚C in still air. The LM35 is rated to operate over a −55˚ to +150˚C temperature range,
while the LM35C is rated for a −40˚ to +110˚C range (−10˚ with improved accuracy). The
LM35 series is available packaged in hermetic TO-46 transistor packages, while the LM35C,
LM35CA, and LM35D are also available in the plastic TO-92 transistor package. The
LM35D is also available in an 8-lead surface mount small outline package and a plastic TO-
220 package.
Features of LM35
• Calibrated directly in ˚ Celsius (Centigrade)
• Linear + 10.0 mV/˚C scale factor
• 0.5˚C accuracy guarantee able (at +25˚C)
• Rated for full −55˚ to +150˚C range
• Suitable for remote applications
• Low cost due to wafer-level trimming
• Operates from 4 to 30 volts
• Less than 60 µA current drain
• Low self-heating, 0.08˚C in still air
• Nonlinearity only ±1⁄4˚C typical
• Low impedance output, 0.1 Ω for 1 mA load

2.5.1 Pin description of LM35

Pin description of LM35 is shown in Fig. 2.3(a).

Fig. 2.3 (a) Pin Description of LM35

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2.5.2 Interfacing LM35 with Arduino
Temperature sensor LM35 is interfaced to the Arduino through the analog input pins A0,
GND and VCC. Analog input pin VCC is made high and it acts as the 5V supply pin for the
LM35. Analog input pin GND is made low and it acts as the ground pin for the LM35.
Analog input pin A0 is set as an input and the voltage output of LM35 is coupled to the
Arduino through this pin. Interfacing of LM35 with Arduino is shown is Fig. 2.3 (b).

Fig. 2.3 (b) Interfacing of LM35 with Arduino

2.6 LIQUID CRYSTAL DISPLAY (LCD)
Liquid Crystal Display (LCD) screen is an electronic display module which finds a
wide range of applications. 16x2 LCD display is a very basic module and is very commonly
used in various devices and circuits. These modules are preferred over seven segments and
other multi segment LEDs. The reasons being, LCDs are economical, easily programmable,
have no limitations of displaying special and even custom characters (unlike in seven
segments), animations and lot of other useful features. A 16x2 LCD means it can display 16
characters per line and there are 2 such lines. In this LCD each character is displayed in 5x7
pixel matrix. This LCD has two registers, command and data. The command register stores
the command instructions given to the LCD. A command is an instruction given to the LCD
to do a predefined task like initializing it, clearing its screen, setting the cursor position,
controlling display etc. The data register stores the data to be displayed on the LCD. The data
is the ASCII value of the character to be displayed on the LCD. Pin diagram of LCD is
shown in Fig. 2.4 and details of its pin configuration are given Table 2.3.

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 Fig. 2.4 LCD Pin Diagram
Table 2.3 Pin Configuration of LCD

PIN NO. SYMBOL I/O DESCRIPTION

1 VSS -- Ground
2 VDD -- +5V power supply
3 VE -- Power supply to control contrast

RS=0 to select command register

4 RS I
RS=1 to select data register
R/W=0 for write
5 R/W I
R/W=1 for read
6 EN I/O Enable
7 DB0 I/O The 8-bit data bus
8 DB1 I/O The 8-bit data bus
9 DB2 I/O The 8-bit data bus
10 DB3 I/O The 8-bit data bus
11 DB4 I/O The 8-bit data bus
12 DB5 I/O The 8-bit data bus
13 DB6 I/O The 8-bit data bus
14 DB7 I/O The 8-bit data bus
15 +LED -- LED Back light anode
16 -LED -- LED Back light cathode

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2.7 RELAY DRIVER
ULN is mainly suited for interfacing low-level circuits with multiple peripheral power
loads. The series ULN20XX have high voltage, high current Darlington arrays feature
continuous load current ratings. The pin diagrams and one pair of Darlington connection of
ULN2003A is shown in Fig. 2.5 (a) and (b) respectively.

(a) (b)
Fig. 2.5 (a) Pin Diagrams of ULN2003A (b) One Pair of Darlington Connection
The driver makes use of the ULN2003Adriver IC, which contains an array of 7 power
Darlington arrays, each capable of driving 500mA of current. At an approximate duty-cycle,
depending on ambient temperature and number of drivers turned on, simultaneously typical
power loads totaling over 230W can be controlled. If the logic at input 1B is high then the
output at its corresponding pin 1C will be low. The device has base resistors, allowing direct
connection to any common logic family. All the emitters are tied together and brought out to
a separate terminal. Output protection diodes are included; hence the device can drive
inductive loads with minimum extra components. Typical loads include relays, solenoids, DC
motors, stepper motors, magnetic print hammers, multiplexed LED, incandescent displays
and heaters etc.

2.8 RELAY
A relay is an electrical switch that opens and closes under control of another electrical
circuit. In the original form, the switch is operated by an electromagnet to open or close one
or many sets of contacts. These contacts can be either normally open (NO), normally closed
(NC) or change-over contacts. Normally-open contacts connect the circuit when the relay is
activated. The circuit is disconnected when the relay is inactive. It is also called Form A

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contact or "make" contact. Forming a contact is ideal for applications that require switching a
high-current power source from a remote device. For example a low voltage battery circuit
can use a relay to switch a 230V AC mains circuit. Normally-closed contacts disconnect the
circuit when the relay is activated; the circuit is connected when the relay is inactive. It is also
called Form B contact or "break" contact. Form B contact is ideal for applications that require
the circuit to remain closed until the relay is activated. Change-over contacts control two
circuits one normally-open contact and second is normally-closed contact with a common
terminal. Fig. 2.6 shows the relays.

Fig. 2.6 Relays

2.8.1 Working of Relay
Relay allows one circuit to switch a second circuit which is completely separate from the
first. There is no electrical connection inside the relay between the two circuits and the link is
magnetic and mechanical. When a current flows through the coil, the resulting magnetic field
attracts an armature that is mechanically linked to a moving contact. The movement either
makes or breaks a connection with a fixed contact. When the current to the coil is switched
OFF, the armature is returned by a force that is half as strong as the magnetic force to its
relaxed position. The magnetic flux in the armature induces a current in opposition to the
current provided to the coil called 'back EMF. There is a rush of current to operate the coil
and move the contacts, but once the armature is closed, the current required to hold the
armature closed is a small fraction of that, typically one tenth. Relays are manufactured to
operate quickly. In a low voltage application, this is used to reduce noise. In a high voltage or
high current application, this is used to reduce arcing. The basic switching process of relay
from one circuit to the other circuit is shown in Fig. 2.7.

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 Fig. 2.7 Switching Process of Relay from One Circuit to the Other Circuit

2.9 PASSIVE COMPONENTS

Passive Components are electronic components that do not require a Source of Energy to
perform their intended functions. Resistors, capacitors and inductors are the main three
passive components. In our circuit we use resistors and capacitors only.

2.9.1 Resistors
A resistor is a two-terminal electronic component that produces a voltage across its
terminals that is proportional to the electric current passing through it in accordance with
Ohm's law: V IR ……………. (1)

Resistors are elements of electrical networks and electronic circuits and are simplest in most
electronic equipment. Practical resistors can be made of various compounds and films, as
well as wire made of a high-resistivity alloy, such as nickel/chrome etc. The primary
characteristics of a resistor are the resistance, the tolerance, maximum working voltage and
the power rating. Critical resistance is determined by the design, materials and dimensions of
the resistor. Resistors can be made to control the flow of current, to work as voltage dividers,
to dissipate power and it can shape electrical waves when used in combination of other
components. Basic unit of a resistance is ohm. A resistor is shown in Fig. 2.8.

Fig. 2.8 Resistor

The power dissipated by a resistor (or the equivalent resistance of a resistor network) is
calculated using the following formula:

R …………………. (2)

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Where V is Voltage across a resister
I is current through a resister
R is a resister
P is power dissipated by a resister

2.9.2 Capacitors
The capacitor or sometimes referred to as a condenser, is a passive device, which
stores energy in the form of electrostatic field which produces a potential (static voltage)
across its plates. In its basic form, a capacitor consists of two parallel conductive plates that
are not connected but are electrically separated either by air or by an insulating material
called the dielectric. When a voltage is applied across these plates, a current starts flowing
charging up the plates with electrons giving one plate a positive charge and the other plate an
equal and opposite negative charge. This flow of electrons to the plates is known as the
charging current and continues to flow until the voltage across the plates (and hence the
capacitor) is equal to the applied voltage Vc. At this point, the capacitor is said to be fully
charged which is illustrated in Fig. 2.9 (a). Electrolytic capacitors are shown in Fig. 2.9 (b).

(a) (b)
Fig. 2.9 (a) Construction of Capacitor (b) Electrolytic Capacitor

2.10 LIGHT EMITTING DIODE (LED)

LED was introduced as a practical electronic component in 1962. Previous LEDs
emitted low-intensity red light, but modern versions are available across the visible,
ultraviolet and infrared wavelengths, with very high brightness. The internal structure and
different shapes of a LED are shown in Fig. 2.10 (a) and (b) respectively.

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 (a) (b)
Fig. 2.10 (a) Inside a LED (b) Different Shapes of LED

2.10.1 Working of LED

A light-emitting diode (LED) is basically a semiconductor p-n junction diode. When it is
forward biased, electrons are able to recombine with holes within the device, releasing
energy in the form of photons (light). This effect is called electroluminescence and is shown
in Fig. 2.11 (a) while the symbol of LED is shown in Fig. 2.11 (b).

(a) (b)
Fig. 2.11 (a) Recombination process in LED (b) Symbol of LED
The color of the light (corresponding to the energy of the photon) is determined by the
energy band gap of the semiconductor. In Si and Ge diodes, the greater percentage of the
energy is converted during recombination at the junction and is dissipated in the form of heat
within the structure, and the emitted light is negligible. That is why Si and Ge are not used in
the construction of LED devices. The various advantages of LED are listed as follows:
➢ Smaller in size
➢ Light in weight
➢ Mechanically rugged
➢ Lower operating temperature
➢ Small energy consumption
➢ On time is very small

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 ➢ Available in different colors
➢ Larger life as compared to lamp
➢ Low cost
➢ No complex driver circuitry is required

In addition, there are some disadvantages also which are listed as below:
➢ Gets damage due to over voltage and over current
➢ Quantum efficiency is low

2.11 VOLTAGE REGULATOR

A voltage regulator (also called a 'regulator') with only three terminals appears to be a
simple device, but it is in fact a very complex integrated circuit. It converts a varying input
voltage into a constant 'regulated' output voltage. Voltage regulators are available in a variety
of outputs like 5V, 6V, 9V, 12V and 15V etc. The LM78XX series of voltage regulators are
designed for positive input. Fig. 2.12 shows a voltage regulator.

Fig. 2.12 Voltage Regulator

On the other hand, for applications requiring negative input, the LM79XX series is used.
Using a pair of 'voltage-divider' resistors can increase the output voltage of a regulator circuit.
It is not possible to obtain a voltage lower than the stated rating. One cannot use a 12V
regulator to make a 5V power supply. Voltage regulators are very robust. These can
withstand over current drawn due to short circuits and can also bear over-heating. In both the
cases, the regulator will cut off before any damage occurs. The only way to destroy a
regulator is to apply reverse voltage to its input. Reverse polarity destroys the regulator
almost instantly.

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2.12 BUZZER
A buzzer or beeper is an audio signalling device, which may be mechanical,
electromechanical, or piezoelectric. Typical uses of buzzers and beepers include alarm
devices, timers and confirmation of user input. Electronic buzzer and its symbol are shown in
the Fig. 2.13 (a) and (b) respectively.

(a) (b)
Fig. 2.13 (a) Electronic Buzzer (b) Symbol

2.13 TRANSISTORS
Bipolar junction transistors consist of a three-layer sandwich of doped semiconductor
materials. We have two types of bipolar junction transistors: the N-P-N and the P-N-P. Each
layer has a pin. On bipolar junction transistors the three pins are labeled as:
• Collector (C)
• Base (B)
• Emitter (E)
Fig. 2.14 shows NPN and PNP transistor with their symbols.

Fig. 2.14 NPN and PNP Transistor

In this chapter we have discussed the block diagram and components required to construct the
proposed project. In next chapter we will explain the circuit diagram and hardware used in
detail.

In this chapter we have discussed the block diagram and components required to construct the
proposed project. In next chapter we will explain the circuit diagram and hardware used in
detail.

21
 CHAPTER THREE
EXECUTION OF THE PROJECT HARDWARE
3.1 IMPLEMENTATION OF THE HARDWARE
This chapter explains step by step methodology adopted to develop hardware of the overall
proposed system. The main objective is to build a general system to obtain data from
temperature sensor and manipulate it to achieve a specific output.

3.2 CIRCUIT DIAGRAM OF THE HARDWARE

Circuit diagram for the temperature controlled fan used in industry is shown in
Fig. 3.1 (a) and (b). The Arduino pro mini is used in this hardware model, which is the heart
of this system and has already been explained in previous chapter.

Fig. 3.1 (a) Circuit Diagram for Temperature Controlled Fan Used in Industry

22
 1 7805 IC 3

2 5V
12V
10K 1000µF/25V

Fig. 3.1 (b) Circuit Diagram for Power Supply

3.3 WORKING OF THE PROJECT
The working of this project is as explained below:
➢ If temperature increases (let greater than 40 degree Centigrade) then sensor output
increases from 0 to 1023, because in this sensor we use analog output of 10 bit
resolutions.
➢ This situation will be considered as an alarming situation, so controller will automatically
turn on the fan connected with relay. A buzzer will automatically beep with LED as an
indicator for alarming situation.
➢ When sensor reading again decreases below the threshold level (let less than 40 degree
centigrade) then fan, buzzer and LED will be automatically switched off by the controller.
➢ The variation of temperature is continuously displayed on the LCD. Alarming situation
and status of the fan will also be displayed on the LCD.
➢ By programming the Arduino pro mini we can easily change the threshold value for
switching the relay and alarming situation.
➢ Microcontroller do not operate relay directly because relay needs more current to operate
and microcontroller is not able to provide this much amount of current, so we need
transistor BC 547 as a relay driver to operate the relay.

In this chapter we have explained the circuitry, hardware used and working of the proposed
project. In next chapter we will discuss the software and PCB making process in detail.

23
 CHAPTER FOUR
EXECUTION OF THE PROJECT SOFTWARE
4.1 SOFTWARE FOR PCB MAKING
DIP Trace has been used for designing PCB and this software is freely available on internet.
On down loading this software, PCBs can be easily prepared according to requirement of the
circuitry as shown in Fig. 4.1.

Fig. 4.1 PCB for Temperature Controlled Fan Used in Industry

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4.2 DOWNLOADING ARDUINO IDE (ARDUINO PROGRAMMING
SOFTWARE)
We can load new programs on the main chip Arduino pro mini via separate burner using the
Arduino IDE. This is an open source platform and purchase of license is not required. The
Arduino IDE is supported by Window, Mac OS X and also Linux. We can visit the link
below to download the latest Arduino IDE:
➢ http://arduino.cc/en/Main/Software
For Arduino software, we first download and extract it out and save it anywhere we like.
Next, to start create a project; we double click on the arduino.exe icon as shown in Fig. 4.2.
We can find this icon on desktop or start windows. This will allow us to open the Arduino
IDE. Next we choose the Arduino board using for the first time such as in Fig. 4.3. For
selecting the board, go to Tools > Board >Arduino Pro or Pro Mini.

Fig. 4.2 Arduino.exe Icon

SELECT
ARDUINO PRO MINI
2560

Fig. 4.3 Selection of Arduino Pro Mini

25
We may also choose the COM port for Arduino Mega Pro mini as shown in Fig. 4.4. Go to
Tools > Port > COM3 (Depend on the PC).

TICK THE COM PORT

Fig. 4.4 Selection of COM Port

4.3 UPLOADING AN ARDUINO SKETCH (PROGRAM)

After Connecting Arduino pro mini to computer via burner, first of all we will upload the
most basic example, which is blinking an on-board LED using digital pin 13. Open Arduino
IDE. Go to File > Examples > 01.Basics > Blink as shown in Fig. 4.5.

BLINK
PROGRAM

Fig. 4.5 Selection of LED Blink Program on Digital Pin 13

26
 By default, Arduino IDE is available pre-configured for the Arduino pro mini. After
compiling the sketch (program) click the “Upload” button and wait a few seconds until a
“Done uploading” message appears as shown in Fig. 4.6.

COMPILE
UPLOAD BUTTON
BUTTON

DONE UPLOADING
MESSAGE

Fig. 4.6 Compilation and Uploading the Program on to the Arduino Pro Mini

This code simply blinks on-board LED on Arduino pro mini, highlighted with red color as
shown in Fig. 4.7. If we look closely we should see the LED staying on for one second and
off for another second repeatedly.

ON-BOARD
LED BLINK
FOR EVERY 1
SEC.

Fig. 4.7 Blinking of On-Board LED for the Arduino Pro Mini

The developed hardware program is burnt in a similar way as explained earlier for “blink”
program on Arduino Pro Mini through Arduino IDE. This programming language is very
27
much similar to C language however Arduino provides specific libraries, used only in this
environment.

In this chapter we have discussed regarding the execution of hardware and software in detail
including PCB making process. In next chapter we are going to explain the results, discussion
and analysis regarding temperature controlled fan used in industry.

28
 CHAPTER FIVE
RESULTS, DISCUSSION AND ANALYSIS
5.1 INTRODUCTION
This hardware provides an effective and efficient solution to temperature controlled fan used
in industry. The circuit is designed considering simplicity as the first priority and secondly in
an economic way. So the components are also taken as simple as possible, which are very
cheap in cost and easily available in the market.

We have tested the performance of the circuit in real time. When the temperature increases
above the threshold level then relay is operated and a fan will automatically start to cool the
temperature. Status of the fan is also displayed on the LCD.

In alarming situation when temperature increases (let it be greater than 40 degree Centigrade)
then sensor output increases from 0 to 1023, when sensor reading again decreases below the
threshold level (less than 40 degree centigrade) then fan, buzzer and LED are automatically
switched off by the controller.

The variation of temperature is continuously displayed on the LCD. Alarming situation and
status of the fan are also displayed on the LCD.

A hardware model of the system has been developed as shown in Fig. 5.1.

Fig. 5.1 (a) Original Pictures of Hardware Model

29
 FAN

RELAY BUZZER

TEMP. SENSOR

ARDUINO PROMINI

LCD

Fig. 5.1 (b) Original Pictures of Hardware Model

30
 Fig. 5.1 (c) Original Pictures of Hardware Model

31
5.2 COST CALCULATION OF THE HARDWARE MODEL
The cost of the hardware model implemented has been given in Table 5.1.
Table 5.1 Cost of the Hardware Model
AMOUNT
Sr. NO. COMPONENT(S) QUANTITY RATE
IN Rs.
1 Arduino Pro Mini 1 400 400
2 16x2 LCD 1 200 200
3 Temperature sensor (LM35) 1 50 50
4 Relay 12V 1 25 25
5 Transistor 1 4 4
6 Buzzer 1 15 15
7 IC 7805 1 20 20
8 Capacitor (1000µF/25V) 1 15 15
9 LED’s (Different Color) 2 1 2
10 Diode 1 1 1
11 Resistance (1 560Ω, 1 1kΩ & 1 10kΩ) ---- 5 5
12 DC Socket 1 15 15
13 DC adapter (12V/1A) 1 200 200
14 Mail & Female headers pin ---- 50 50
15 POT (103) 1 20 20
16 PCB making charges ---- 800 800
17 Board and other miscellaneous charges ---- 500 500
Total 2322

The cost analysis of this system shows that implementation of this system is very cheap.

32
 CHAPTER SIX
CONCLUSIONS AND FUTURE SCOPE

6.1 CONCLUSIONS

The circuit is very simple and easy to build. This project elaborates the design and
construction of temperature controlled fan used in industry. As conclusion, the system which
is designed in this work performs very well for any temperature change and can be classified
as automatic control.

6.2 FUTURE SCOPE

The proposed hardware, along with some modification can be used for the purpose such
as;
• This circuit can be expanded by incorporating a passive infrared sensor along with the
temperature sensor. The passive infrared sensor can include a Fresnel lens for sensing a
360° circumference beneath the fan so that the fan can be turned on and off based the
motion of persons approaching and leaving a selected area.

• A change over switch can be connected further using which the Fan can be controlled
manually as well as automatically.

• This temperature controlled fan with some modifications can further be used in other
Heater Circuits to maintain the constant temperature of the device.

• With this circuit, an alarm circuit can be added and used effectively in large equipments
where the risk of being overheated and explosions are the serious problems, in various
industries.

33
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