DIY Fan Project! Build Your Own Fan with AC/DC Control Module 🔥

$5 10pcs 1-2 layer PCB Order from PCBWay: https://www.pcbway.com/?from=technology4power

Controlling a 12V fan using both AC and DC inputs is essential for various applications like UPS systems, solar setups, and emergency ventilation. This guide will walk you through building a reliable 12V AC/DC fan controller module using a 12V 3000mA transformer, diodes, and other essential components. We'll also introduce a compatible PCB design from PCBWay to streamline your project.

🧰 Components Required

Here's a detailed list of components you'll need:

12V 3000mA Transformer – 1 piece
Steps down 220V AC to 12V AC.
1N5408 Diode – 2 pieces
Used for full-wave rectification.
1N5822 Diode – 3 pieces
Fast recovery diodes for efficient switching and reverse protection.
1N5819 Diode – 1 piece
Protects the battery from reverse current.
2200µF Electrolytic Capacitor – 1 piece
Smooths the rectified DC voltage.
220µF Electrolytic Capacitor – 1 piece
Further filters the DC voltage.
10kΩ Resistor – 2 pieces
Used in voltage dividers and biasing circuits.
1kΩ Resistor – 2 pieces
Limits current to LEDs and other components.
LM2596T-ADJ Voltage Regulator – 1 piece
Adjustable step-down voltage regulator for stable output.
AUIP0540N N-Channel MOSFET – 1 piece
Acts as a switch to control the fan load efficiently.
880µH Inductor – 1 piece
Filters out voltage spikes and noise.
5mm Red LED – 1 piece
Indicates power status.
SPST Switch – 1 piece
Manual control for turning the fan on or off.
3-Pin Connector – 1 piece
For connecting the fan.
2-Pin Connector – 2 pieces
For AC and DC power inputs.
PCB Board – 1 piece
Mounts and connects all components.
Heat Sink for LM2596T – 1 piece (optional but recommended)
Dissipates heat from the voltage regulator.
Fuse or Polyfuse – 1 piece (optional for protection)
Protects the circuit from overcurrent.

🖼️ Schematic Overview

$5 10pcs 1-2 layer PCB Order from PCBWay: https://www.pcbway.com/?from=technology4power

The circuit is designed to automatically switch between AC and DC inputs to power a 12V fan. When AC power is available, the transformer steps down the voltage, which is then rectified and regulated to power the fan. In the absence of AC power, the circuit seamlessly switches to a 12V DC battery input. The MOSFET controls the fan operation, and the LED indicates power status.

🔌 How the Circuit Works

AC Input to DC Conversion:
1. The 12V 3000mA transformer reduces 220V AC to 12V AC.
2. 1N5408 diodes form a full-wave rectifier.
3. The 2200µF capacitor smooths the rectified voltage.
Voltage Regulation:
1. The LM2596T-ADJ regulator provides a stable 12V DC output.
Battery Integration:
1. The 1N5819 diode prevents reverse current from the battery.
2. In the absence of AC power, the circuit switches to battery power.
Fan Load Control:
1. The AUIP0540N MOSFET acts as a switch to control the fan.
2. A manual SPST switch allows for manual control.
Status Indication:
1. A 5mm red LED indicates the presence of power

🛠️ Assembly Tips

Heat Dissipation: Attach a heat sink to the LM2596T regulator to prevent overheating.
Component Orientation: Ensure diodes and electrolytic capacitors are oriented correctly to prevent malfunction.
Testing: Before connecting the fan, test the output voltage with a multimeter to ensure proper operation.
Protection: Consider adding a fuse or polyfuse to protect against overcurrent situations.

🖥️ Recommended PCB Design from PCBWay

To simplify your project, you can utilize a pre-designed PCB layout available on PCBWay. One such design is a 12V fan controller that supports both AC and DC inputs and includes temperature-based fan speed control.

Key Features:

Dual Power Input: Accepts AC (8V to 17V) or DC (12V to 24V) inputs.PCBWay
Fan Control: Supports up to 2A fan current, with speed control based on temperature.PCBWay
Compact Size: The PCB measures 4.3 x 4.3 cm, making it suitable for various enclosures.PCBWay
Additional Features: Includes a VR to adjust fan sensitivity and an NTC thermistor for temperature sensing.PCBWay

Video Reference:

🧠 Final Thoughts

Building a 12V AC/DC fan controller is a practical project that enhances your understanding of power electronics. By integrating a PCB design from PCBWay, you can achieve a professional and reliable setup. Whether you're a hobbyist or working on a commercial application, this project offers a robust solution for fan control needs.