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Abstract

Digital (Fan) Regulator is one of the applications of electronics

to increase the facilities of life. Fan is one of the unavoidable
Electronic equipment in our day to day life. It has become
essential element without which people can’t lead a smooth
life. The presence of a fan in a house or office is not now
considered as a luxury on the other hand it is included in the
basic requirement. The uses of new electronic theories have
been put down by expertise to increase the facilities given by
the existing appliance. Here the facility of ordinary fan is
increased by the making its speed digitally displayed.

In digital fan regulator we can regulate the speed of the fan by

using tactile button. Here the variation in the square wave
counts of IC (NE555) is used for regulating the speed.

A Tactile button can be used for controlling speed of the fan.

Using this circuit, we can change the speed of the fan. This
circuit is used for controlling the speed of the fan in 5 levels.
This innovation can be a success only if people are made aware
about its advantages and how user-friendly it is. The circuit can
be used to regulate the intensity of light, maintain the change
of accuracy. This innovation finds its use mainly to help the
industry where accuracy is needed in every moment.

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So this topic was chosen for the necessity of regulation and the
concept is based on the basic regulation prototype was thought
in mind and the concept of doing this project was undertaken.

Project Image

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Introduction

The circuit presented here is that of a digital fan regulator,

variable to provide five speeds levels as catered for in ordinary
fan regulators. The circuit makes use of easily available
components. An optional 7-segment display with its associated
circuitry has been provided to display your choice of fan speed.

The heart of the circuit is a module-6 binary counter, built

around IC2 and IC3 (IC 74LS76) which is dual JK flip-flops. The
counter counts up in a straight binary progression from 000 to
101 (i.e. from 0 to 5) upon each successive clock edge and is
reset to 000 upon next clock. The count sequence of the
counter has been summarised in Table 1.

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Block diagram

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BLOCK
DIAGRAM
DESCRIPTIO
N
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Transformer

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A transformer is a device that transfers electrical energy from

one circuit to another through inductively coupled conductors
— the transformer's coils or "windings". Transformer is used
here to step down the supply voltage to a level suitable for the
low voltage components.

The transformer used here is a 230/ (9V-0-9V) step down

transformer. 

Regulator (IC 7805)

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A voltage regulator is an electrical regulator designed to

automatically maintain a constant voltage level.

IC 7805 is used here. It is a 5V regulator. It regulates the

rectified 9V to 5V. This 5V is supplied to the whole circuit.

Capacitor
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A capacitor (formerly known as condenser) is a device for

storing electric charge. The forms of practical capacitors vary
widely, but all contain at least two conductors separated by a
non-conductor. Capacitors used as parts of electrical systems,
for example, consist of metal foils separated by a layer of
insulating film.

Here, Capacitors used for noise filter.

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Monostable Multivibrator (NE 555)

A multivibrator is an electronic circuit used to implement a

variety of simple two-state systems such as oscillators, timers
and flip-flops. A monostable multivibrator, as its name
indicates, has a stable state and a quasi-stable state. An
external trigger must be applied to change from the stable
state to the quasi-stable state.

Here, a NE 555 IC is wired as monostable multivibrator. The

trigger to the multivibrator is the signal from the switch. This

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multivibrator is used to delay the clock pulse of the decade

counter.

Flip flop (IC HD74LS76)

A flip-flop or latch is a circuit that has two stable states and can
be used to store state information. The circuit can be made to
change state by signals applied to one or more control inputs
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and will have one or two outputs. Flip-flops and latches are a
fundamental building block of digital electronics systems used
in computers, communications, and many other types of
systems.

Flip-flops and latches are used as data storage elements. Such

data storage can be used for storage of state, and such a circuit
is described as sequential logic. It can also be used for counting
of pulses, and for synchronizing variably-timed input signals to
some reference timing signal.

Decoder (IC 74LS138)

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A decoder is a device which does the reverse of an encoder,

undoing the encoding so that the original information can be
retrieved. The same method used to encode is usually just
reversed in order to decode.

In digital electronics, a decoder can take the form of a multiple-

input, multiple-output logic circuit that converts coded inputs
into coded outputs, where the input and output codes are
different. e.g. n-to-2n, binary-coded decimal decoders. Enable
inputs must be on for the decoder to function, otherwise its
outputs assume a single "disabled" output code word. Decoding
is necessary in applications such as data multiplexing, 7
segment display and memory address decoding.

Seven Segment Display (FND)

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A seven-segment display, or seven-segment indicator, is a form

of electronic display device for displaying decimal numerals
that is an alternative to the more complex dot-matrix displays.
Seven-segment displays are widely used in digital clocks,
electronic meters, and other electronic devices for displaying
numerical information.

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Circuit Diagram

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Working Principle

Let us begin with the assumption that the counter reads 000 at
power ON. The monoshot built around IC1 (NE 555) provides
necessary pulses to trigger the counter upon every depression
of switch S1. Upon the arrival of first edge, the counter
advances to 001. The outputs of the counter go to IC4 (IC
74138), which is a 3-line to 8-line decoder. When IC4 receives
the input address 001, its output Q1 goes low, while other
outputs Q0 & Q2 through Q7 stay high. The output Q1, after
inversion, drives transistor T1, which actuates relay RL1. Now
power is delivered to the fan through N/O contact RL1/1 of relay
RL1 and the tapped resistor RT. For the tapped resistor RT, one
can use the resistance found in conventional fan regulators
with rotary speed regulation.

The outputs of the counter also go to IC6 (IC 7447), a BCD to 7-

segment code converter, which, in turn, drives a 7-segment
LED display. When switch S1 is depressed once again, the
counter advances to count 010. Now, the output Q2 of IC4 goes
low, while Q0, Q1 and Q3 through Q7 go high or remain high. This
forces transistor T2 to saturation and actuates relay RL2. The
display indicates the counter output in a 7-segment fashion.

The counter proceeds through its normal count sequence upon

every depression of switch S1 up to the count 101. When switch
S1 is depressed once again, normally the counter should read
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110. But the two most significant bits of the counter force the
output of NAND gate (IC7) to go low to reset the counter to 000.
The counter now begins to count through its normal sequence
all over again, upon every key depression.

The circuit does not provide the facility to memorise its

previous setting once it is powered OFF or when there is mains
failure.

Components list

1. IC 555 Timer

2. IC 74LS76, IC 7447, IC 74LS00, IC 74LS138, IC 7404

3. Transformer – 230/(9V -0-9V)

4. FND (CA)

5. Voltage Regulator IC 7805

6. Capacitor 1000/25V,10/50V

7. Capacitor 104 (.1),103 (.01)

8. Resistors – 100K, 22K, 220 Ω

9. PCB

10. Vero board (Power Supply)

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11. Led (5mm)

PCB Fabrication

Printed Circuit Boards (PCB) play a vital role here in

determining the overall performance of the electronic
equipment. A good PCB design ensures that the noise
introduced as a result of component placement and track
layout is held within limits while still providing components
years of assembly maintenance and performance reliability.

Printed circuits boards are used to route electric signals

through copper track which are firmly bonded to an insulating
base.

Advantages of PCB over common wiring

• PCB’s are necessary for connecting a large number of
electronic components in a very small area with minimum
parasitic effects.
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• PCB’s are simulated with mass production with less

chance of writing error.
• Small components are easily mounted.
• Servicing is simplified.

The base materials used for PCB’s are glass epoxy, epoxy
paper, polyester etc. Copper foil used for copper clad is
manufactured by the process of electronic deposition.

The properties of copper foil are:

35μ
Thickness:
meter
Thickness +5 μ
tolerance: meter
Purity of
99.8%
Copper:
Resistivity at
0.1594
20°C:

Preparation of Single Sided PCB

In a single sided PCB the conductor tracks run only on one side
of copper clad board. Thus crossing of conductors is not
allowed. Base materials are selected according to application. It
is mechanically and chemically cleansed. The photo resist is an
organic solution which when exposed to light of proper
wavelength, changes their solubility in developer but after
exposure to light is not soluble. Laminate coating of photo
resist is done by

(i) Spray coating

(ii) Dip coating

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(iii) Roller coating.

The coated copper clad and laminated film negative is kept in

intimate contact with each other.

The assembly is exposed to UV light and is rinsed in the

developer tank. Proper developer has to be used for a
particular photo resist and then the PCB is dyed in a tray. The
dye reveals the flux to be used for a particular photo resist.
Then the PCB is dyed in a tray.

Fabrication
The required circuit is designed and the layout of the circuit is
done on the component side as well as the copper clad side.
Spaces are provided for holes to insert the respective
components. Etch resistant ink coatings are given on the
interconnecting marks.

Etching
The copper clad PCB is etched with ferrous chloride solution
containing a small amount of Hydro Chloric Acid for increasing
activeness of Ferric Chloride in etching. Wherever, the varnish
coating is there the copper remains. Then it is washed with
water and Oxalic Acid.

Drilling
The required holes of suitable size are drilled using twist drill.
Now the Printed Circuit Board (PCB) is complete and ready for
soldering.
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Soldering
Soldering is the process of joining of two metals using an alloy
solder consisting of Tin and Lead (Sn-Pb). Tin determines the
melting whereas the Lead is used to reduce the cost. After the
PCB fabrication is done, the various components are arranged
at proper locations on the PCB and then the soldering is done.
All liquids consist of particles which attract each other. The
surface is always trying to shrink and this is because of surface
tension. The principle behind soldering is that when liquid
particles are brought in contact with the walls of the solid
surface, it may happen that the solid attracts the liquid surface.
This property is called adhesive property. Care must be taken
that the melting point of solder is below that of the metal so
that its surface is melted without melting without the metal.

Flux
During the soldering process the flux acts as a medium for
improving the degree of melting. The basic functions of flux are
mentioned below:

• Removes oxide from the surface.

• Assists the transfer of heat from the source to the joining
and provides a liquid cover including air gap.
• Removal of residue after the completion of the soldering
operation.

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PCB Layout

The layout can be done either by hand or by using PCB

designing software like ORCAD or Circuit Maker

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Application

• Digital Fan regulator based project board is used for

regulator purpose.
Such as Fans, Motors etc.
• It can be used to control the intensity of various types of
lights i.e. ‘Dimmer’

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Advantage

• This circuit is simple to use and efficient.

• It can be assembled with ease.
• It is cheap and hence very economic.
• It is small in size.
• Thus by this project, any sort of regulation can be
achieved.

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Future development

This digital fan regulator can be improved by the following

ways:

• In future aspect, adding an IR system will improve the

system so the speed change technique will be précised &

accurate. [TSOP 1738]

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• Adding temperature sensor will improve the system

therefore the speed will gradually increase each time

when the heat increases. [PT100 / RTD]

• The project can be further incorporated with lights to

increase / decrease the intensity/illumination. [dimmer]

• Besides, this concept can be moved to industry sectors

such as in induction motor which can be operated

remotely by this project.

• High amount of current can also be operated by this

project.

Conclusion
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With the knowledge of new techniques in ‘Electronics’ we are

able to make our life more comfortable. One such application of
electronics is used in “Digital Fan Regulator”.

The same circuit finds its use in many more applications. By

this concept we can create various regulator systems that
mainly used in industries.

I feel that our product serves something good to this world and
we like to present it before this prosperous world.

Reference
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• [Link]

• [Link]

• Electronics for you magazines

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