Variable Speed
How would I design a mechanical/ electronic system to detect cooling fan movement on a variable speed drive?
It must be capable of detecting; Is fan on, speed of fan, number of blades and direction of fan movement clockwise/ anticlockwise.
If you can give a list of ideas that would be great.
Thanks in advance.
>> Is fan on, speed of fan, number of blades and direction of fan movement clockwise/ anticlockwise. <<
As mentioned in another answer you would already know the number of blades and designed direction of rotation. So I assume you need ideas for some type of school project.
There are many ways to determine speed and direction. The size of the fan and its accessibility will help determine what is practical.
You can use a small permanent magnet DC motor as an electrical generator / tachometer. The fan shaft drives the small generator either by direct drive, friction drive, or chain/belt drive. Obviously this would be for a large fan. (I have seen this used on a forced draft blower and a 3000hp propulsion motor)
The DC motor / generator will create a pulsating DC voltage as its turned by the fan. The amount of voltage and frequency is proportional to the speed, polarity will indicate direction.
For a smaller fan you can use LED's and optical sensors like Cds cells.
Using optical sensors you will need to make two types of tachometers one will compute RPM and a timing mark. The first is a reflective type in which a LED will shine its light onto a spot on the fan blades. Lets position this beam to shine near the hub. On one fan blade you attach a piece of reflective tape. The light will bounce off this reflective spot and strike a light sensor. You only attach reflective tape to one fan blade. This sensor will give you the RPM and a timing mark by which to count pulses from another sensor . Counting pulses in one revolution will let you determine the number of blades.
To determine direction you use two sets of LED/sensors and create a quadrature encoder. The fan blades will interrupt the two light beams the orientation of the two LED/Sensor sets is such that a 90 degree phase relationship is obtained from the square waves generated by the interruption of the light beams. (you could use an encoder disk but you also want to count fan blades)
Using the timing pulse from the RPM tach you count pulses from one of the Quadrature sensor and you will be able to determine the number of fan blades.
You can detect if the fan is running by monitoring the frequency of any of the sensors. You can also monitor if power is being applied to the motor. It is possible for the fan to windmill and rotate due to wind blowing on it so a combination of monitoring power and frequency will verify if the fan is on, off or windmilling.
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