CHAPTER THREE

MATERIALS AND METHODOLOGY

3.1 Materials

The research materials used are outlined below;

1. Dc motor

2. Rechargeable battery

3. Fan blades

4. Battery charger circuit

5. Switch

6. Wire

7. Casing/Housing

8. Screws

9. Resistors, Capacitors and Diodes

10. Fan base/ stand

11. Adjustable tilt mechanism

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3.1.1 DC MOTOR

A DC (Direct Current) motor is a key component in rechargeable

electronic fans, converting electrical energy into mechanical energy to

drive the fan blades and produce airflow.

FIG. 3.1: DC MOTOR

3.1.2 RECHARGEABLE BATTERY

A rechargeable battery is a critical component in a rechargeable fan,

providing the necessary power to operate the fan when it is not connected

to an external power source. Below is an explanation of how a

rechargeable battery works, its basic structures, and its role in a

rechargeable fan.

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 FIG. 3.2 : A RECHARGEABLE BATTERY

3.1.3 FAN BLADES

Fan blades are a crucial component of a rechargeable fan, responsible for

generating airflow by converting the rotational motion of the motor into

kinetic energy. In a rechargeable fan, the fan blades are integral to

generating airflow that provides cooling.

FIG. 3.3 : FAN BLADE

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3.1.4 BATTERY CHARGER CIRCUIT

A battery charger circuit is a critical component in a rechargeable fan,

responsible for safely and efficiently charging the battery when the fan is

connected to an external power source.

FIG. 3.4: BATTERY CHARGER CIRCUIT

3.1.5 SWITCH

A switch in a rechargeable fan is a user interface component that allows the

user to control the operation of the fan, such as turning it on/off, adjusting

speed settings, or activating additional features like oscillation.

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3.1.6 CASING AND HOUSING

The casing or housing of a rechargeable fan is the external structure

that encloses and protects the internal components of the fan, such as the

motor, blades, battery, and wiring. It serves multiple functional, aesthetic,

and safety purposes.

3.1.7 SCREWS

Screws are fasteners that join objects together by applying a twisting force,

providing a secure and stable connection. It is a type of fastener

characterized by a helical ridge, known as a thread, wrapped around a

cylindrical shaft. It is designed to convert rotational motion into linear

motion or to hold objects together by applying torque (rotational force) to

its head. Screws are widely used in mechanical assemblies.

3.1.8 RESISTOR, CAPACITOR AND DIODE

Resistor

A resistor is a passive electrical component that limits or regulates the flow

of electric current in a circuit. It does this by providing resistance,

measured in ohms (Ω).

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 FIG.3.5: RESISTOR.

2. Capacitor

A capacitor is a passive electronic component that stores electrical energy

in an electric field. It consists of two conductive plates separated by an

insulating material (dielectric). Capacitance is measured in farads (F).

FIG. 3.6 : CAPACITOR.

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Diode

A diode is a semiconductor device that allows current to flow in one

direction only. It acts as a one-way valve for electricity.

FIG. 3.7: DIODE

Summary

i. Resistors: Control current flow and voltage levels.

ii. Capacitors: Store energy, filter noise, and stabilize voltage.

iii. Diodes: Ensure one-way current flow and protect the circuit.

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3.1.9 Tools and Equipment

These are the tools and equipment used in manufacturing a rechargeable

fan.

i. Soldering iron

ii. Screw drivers

iii. Wire strippers

iv. Multimeter

v. Pliers.

3.2. METHODS

To achieve the objectives of this project, the following methods were

employed:

3.2.1 To design a portable rechargeable fan with ultimate

convenience

To achieve this objective, we ensured the careful selection and assembly of

components for the rechargeable fan system prototype. We used readily

available and portable materials that are suitable for electrical, mechanical,

and structural applications. Key components, such as the rechargeable

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battery, DC motor, fan blades, and control circuit, were sourced and

meticulously assembled. Additionally, the casing and stand were designed

to enhance portability, durability, and overall user convenience. The

rechargeable battery was chosen based on its high energy capacity and

lightweight nature, allowing prolonged usage without adding excessive

weight. A compact yet powerful DC motor was selected to drive the fan

blades effectively while consuming minimal power. The fan blades were

designed using aerodynamic principles to maximize airflow efficiency

while keeping noise levels low. These components were meticulously

assembled to create a functional system that balances performance and

portability.

To enhance the fan’s structural integrity and ease of use, durable yet

lightweight materials were utilized for the casing and stand. The casing

was designed to protect internal components while ensuring proper

ventilation for heat dissipation. The stand was made adjustable to allow

users to direct airflow at different angles, improving flexibility and

comfort. Additionally, the overall design was compact enough to facilitate

easy transportation and storage, making the fan suitable for various

settings, including homes, offices, and outdoor spaces.

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User convenience was a primary consideration in the assembly process,

leading to the integration of intuitive control features. A simple push-

button interface was incorporated to allow easy operation, enabling users

to adjust fan speeds effortlessly. LED indicators were also added to provide

real-time feedback on battery status and charging progress. The charging

system was optimized to support multiple power sources, such as USB

adapters and solar panels, ensuring usability even in areas with inconsistent

electricity supply. These enhancements made the fan more versatile and

user-friendly.

Finally, rigorous testing was conducted to validate the efficiency,

durability, and portability of the rechargeable fan. Battery performance was

assessed to ensure long-lasting operation, while airflow tests confirmed

effective cooling at different speed settings. The fan was also subjected to

drop tests and vibration tests to evaluate its resilience during transportation

and daily use. The results guided final design refinements, ensuring that the

fan met the objective of ultimate convenience while providing reliable and

sustainable cooling solutions.

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3.2.2 To integrate a rechargeable battery system to enable operation

without direct connection to a power source

To achieve this objective, we made sure that we assessed correct power

requirements to determine the power consumption of the device or system

to also understand the battery capacity needed. Calculate the voltage,

current, and energy requirements to ensure the battery can support the

desired runtime and also in selecting the battery type we made sure to

choose a suitable rechargeable battery based on factors such as energy

density, lifespan, weight, size, and cost. By understanding the power needs

of the fan, we ensured that the battery could support prolonged operation

without frequent recharging. Additionally, factors such as motor efficiency

and speed settings were considered to optimize power usage and enhance

battery performance.

Selecting the right type of battery was crucial for achieving efficiency and

reliability. Various battery options, including lead-acid, nickel-metal

hydride (NiMH), and lithium-ion, were evaluated based on their energy

density, lifespan, size, and cost. Lithium-ion batteries were ultimately

chosen due to their high energy capacity, lightweight design, and longer

lifespan compared to other alternatives. Their ability to charge faster and

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provide consistent voltage output made them ideal for the rechargeable fan,

ensuring stable and long-lasting performance.

To enhance the usability of the battery system, a smart charging circuit was

integrated to regulate power flow and protect the battery from

overcharging or deep discharge. This circuit was designed to automatically

adjust the charging rate based on the battery’s charge level, ensuring

efficient energy storage while prolonging battery life. The system also

incorporated multiple charging options, including USB charging and solar

power compatibility, providing users with greater flexibility in recharging

the fan, especially in areas with unreliable electricity supply.

After integration, rigorous testing was conducted to validate the battery’s

efficiency and reliability. The fan was operated at different speed levels to

assess power consumption under varying conditions. Battery runtime tests

confirmed that the selected battery capacity was sufficient for extended

usage without requiring frequent recharging. Additionally, safety features

such as temperature monitoring and voltage regulation were tested to

ensure the battery system operated safely. These steps ensured that the

rechargeable fan could function effectively without the need for a constant

power connection, meeting the objective of energy independence and user

convenience.

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3.2.3 To construct the fan using appropriate materials, component

and test it’s functionality durability and efficiency

To achieve this objective, we made sure appropriate materials and

components were carefully selected and tested for functionality, durability,

and efficiency. The fan blades were designed to maximize airflow

efficiency, ensuring effective air circulation for cooling, ventilation, and

humidity control. The motor speed was tested at various voltage levels to

achieve optimal performance, and multiple speed settings were

incorporated to provide adjustable airflow for enhanced comfort. To assess

ergonomics and comfort, the fan’s operation was evaluated in different

environments to measure its effectiveness in reducing temperature and

improving air circulation. Noise levels were minimized by using a low-

noise motor, and an adjustable tilt mechanism was added to enhance

usability and convenience.

The fan blades should be made from lightweight yet durable materials like

ABS plastic or aluminum, which provide strength while keeping the fan

portable. The housing or body of the fan can be constructed from impact-

resistant materials such as polycarbonate or reinforced plastic to withstand

daily use and accidental drops. Additionally, rubberized feet or bumpers

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can be added to absorb shocks and prevent slipping, further enhancing

durability.

Next, the components must be carefully selected to ensure optimal

performance. The motor is a critical component, and a brushless DC motor

is often the best choice due to its energy efficiency, quiet operation, and

long lifespan. The rechargeable battery, typically a lithium-ion or lithium-

polymer type, should be chosen based on capacity and runtime

requirements. The charging circuit, including a charging IC and USB port,

must be integrated to allow for safe and efficient recharging. Other

components, such as the control panel (buttons or touch-sensitive controls),

speed settings, and optional features like an LED light, should be designed

for ease of use and added functionality.

Once the fan is assembled, functionality testing is essential to ensure it

operates as intended. This includes verifying that the fan turns on and off

correctly, adjusts speed settings smoothly, and delivers adequate airflow.

The battery's performance should be tested to confirm it meets the

expected runtime and charges efficiently. Any additional features, such as

an auto-off timer or eco mode, should also be tested to ensure they function

properly. User feedback during this phase can help identify any usability

issues or areas for improvement.

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 Durability testing is the next critical step. The fan should be subjected to

various stress tests, such as drop tests, vibration tests, and exposure to

extreme temperatures or humidity, to ensure it can withstand real-world

conditions. Water resistance or splash-proof features, if included, should be

tested to confirm their effectiveness. These tests help identify weak points

in the design and ensure the fan is robust enough for long-term use.

Finally, efficiency testing ensures the fan operates with minimal energy

consumption while delivering maximum performance. This involves

measuring power usage at different speed settings, evaluating the motor's

efficiency, and optimizing the blade design for better airflow with less

noise. The results of these tests can guide adjustments to improve the fan's

overall efficiency. By combining high-quality materials, carefully selected

components, and thorough testing, the fan can achieve a balance of

*functionality, durability, and efficiency*, making it a reliable and user-

friendly product.

Block Diagram of the system

Before carrying out any project, the block diagram must be drawn and fully

understood. Block diagram gives a pictorial understanding of any work. The

block diagram of the system is as below.

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Fig :3.8 Block diagram of the rechargeable Fan

3.3 Principle of Operation

The functional block diagram of rechargeable fan system is shown in

Figure 1. The regulated power supply was designed using a step-down

transformer and rectifying unit. The regulated power supply is used to

convert AC signal to DC for use by the battery charging circuit. The battery

charging unit comprises of electronic components such as capacitors,

resistors, op-amps, diodes, thyristors, transistors and light emitting diodes

(LED).

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 The battery charging circuitry has sections that monitors and detects wrong

battery polarity connector, float charge, full charge indicator status and an

overcharge protection. The electronic components are arranged in such a

way as to achieve a steady float charge on the batter when in use. The

battery charger circuit is responsible for charging the 12V lead acid battery

incorporated in this work at a rechargeable current of 1mA.

The battery used has a cycle voltage of 14.4 – 15V, a standby voltage of

13.5 – 14V and an initial current that is less than 2.1A. The output

comprises of a DC motor to which a fan blade is connected. Current is

supplied to the DC motor by the battery, which in turn energizes the fan

blade for clockwise rotation thereby producing the desired cooling effect.

3.3.1 Circuit Design And Development

The electronic circuit of the rechargeable fan is depicted in Figure 3.8. The

op-amp i.e. LM324 was used as a comparator to monitor voltage at the

terminal of the 12V lead acid battery. This voltage was compared with a

reference threshold of 2.5V set by a thyristor (TL431). When the battery

has a voltage less than the threshold, the op-amp triggers an output that

causes the circuit to commence charging by supplying a current of 1mA. A

yellow LED was used to indicate charging status. When the battery is fully

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charged, the circuit triggers a float charge indicator (i.e. a red LED) to alert

the user. The circuit also has some form of in-built intelligence that

prevents the battery from overcharging thereby ensuring that the battery

voltage is maintained at the specified standby voltage. Any attempt to

exceed this standby voltage, the op-amp cuts supply to the battery.

The entire process is repeated when the battery voltage falls below the

threshold. The charging circuit is also equipped with a wrong battery

polarity connection detecting circuitry. This circuit was incorporated owing

to the fact that wrong polarity connection shortens life span of a battery

thereby reducing its efficiency greatly. A red LED is used to indicate this

occurrence.

A metal structure casing unit was fabricated for the rechargeable electric

fan by cutting, bending and assembly processes. A metal plate of thickness

2mm, length 120cm, and breadth 8cm was cut and bent into a square shape

of equal length. The metal sheet was joined together using a weldering rod

and its accessories. The unit houses the fan blade, the DC motor, the

battery, transformer and the charging circuit. The casing was painted with

silver color for durability and to minimize the effect of humidity and

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 4
4

4
11

11

11
1
2

Figure 3.8 : Automated Charging Circuit Diagram

Labeling of Components

• Resistors (R1, R2, R3, etc.) – Used for current limiting, voltage

division, and setting bias points for transistors.

• Capacitors (C1, C2, etc.) – Used for filtering, decoupling, or timing

purposes in oscillators or amplifiers.

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• Transistors (Q1, Q2, etc.) – Act as switches or amplifiers to control

signal flow.

• Diodes (D1, D2, etc.) – Used for rectification, protection, or signal

conditioning.

• Integrated Circuits (U1, U2, U3, etc.) – Most likely operational

amplifiers or logic gates performing amplification, comparison, or

processing.

• Switch (SW1, SW2, SW3 etc) – Likely a user input or mode

selection switch.

• BAT 1 – Could indicate the positioning of the Battery.

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Figure 3.9 : Prototype of the Developed Rechargeable Fan
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