Ever since the inception of the ceiling fan, it has undergone numerous transformations and modifications over the years. Earlier, single phase induction motors would be used in ceiling fans which later started working on Tesla’s Alternating Current principle. Today, most high-end ceiling fans available in the market operate on DC motors, which are way more powerful and energy efficient than other motors.
DC motors are further classified into two types: Brushed DC and Brushless DC motors. As their names suggest, a brushes DC motor has brushes whereas a brushless DC motor is devoid of brushes.
What Is A DC Brushless Fan?
A brushless DC fan uses brushless DC motors (BLDC motor) that have a cross pattern arrangement of four permanent magnets mounted on the sides of the rotor. Unlike brushed DC motors, BLDC motors do not require any commutator or brushes to operate.
The brushless DC fan is a combination of a powerful BLDC motor, shaft, and fan blades. These fans are durable, reliable, and highly energy efficient. They do not produce sparks in the circuit and operate noiselessly.
The initial torque produced in DC motors is quite high, and hence, brushless DC fans reach their full potential in no time. Their speed can be controlled merely by increasing or decreasing the voltage input.
Brushless DC fans are classified into two categories:
- BLDC fan with Sensor Motor: These fans are equipped with a sensor – called the half effect sensor – that aids in detecting the position of the magnet.
- BLDC fan with Sensor-less Motor: In these fans, back EMF is used to detect the position of the magnet.
Manufacturing And Quality Assurance of the Fan
Like any standard product, DC brushless fans are manufactured maintaining the highest of quality standards. They are usually ISO 9001, and ISO/TS-16949 certified. Maintaining this standard is essential for every fan manufacturer to gain a good hold in the market.
Most reputed companies in the fan industry manufacture brushless DC fans under highly automated environment within an integrated manufacturing system. While the fan parts are produced and assembled by automated technology and robotics, the tests are supervised by expert professionals. Such tests and quality checks for each component of the fan are mandatory to ensure the overall efficiency of the products.
Atomberg technologies is one such manufacturer that produces BLDC fans. These fans not only deliver outstanding air circulation, but they can cut down your energy consumption by 65%! The best thing about Atomberg fans is that they are budget friendly.
Product Research & Development
Every product undergoes constant R&D to improve in terms of quality and efficiency. In fact, technological advancements are imperative to the R&D of ant product. It is through this that products are made better by giving them better attributes, outlook, and shape.
The fan industry is no exception. The DC Brushless Fans that we have today are the result of the labor of a dedicated team of engineers and developers who try and test every possible combination to find the most efficient one. With time, the motor components have been optimized, the fan blade designs have been aerodynamically moderated, and their overall design has become much more attractive.
Today, many BLDC fan manufacturers are relying on new technologies such as Star-LT simulation software, semi-anechoic chambers, CNC (computerized numerical control) machines, and so on to produce high performance and cost-effective products. They are investing a lot of resources in R&D to improve upon their products continually.
DC Brushless Cooling Fan Behaviour
To understand the cooling behavior of a brushless DC fan, you first need to understand the working of its components. However, you can understand the general behavior of the fan by closely following the voltage drops and rises in the power supply. Brushless DC fans have three voltage variants: 12V, 24V and 48V.
Let us try to understand this through a simple example. If a brushless DC fan operates on 12 volts of voltage, then the fan would have an RPM (revolutions per minute) of around 2500. Suppose the voltage now drops to 9 volts, then the RPM of the fan would be reduced to about 1300. Such factors are taken into serious consideration during the testing and R&D of the product to minimize this possibility, that is decreased RPM with less voltage. An efficient brushless DC fan is quite stable and works well even during power fluctuations.