The Knowledge Principles and Internal Structure of DC Brushless Cooling Fans
Category:
Industry Trends
Release time:
2022-04-25
① Brushless DC fan structure: It mainly consists of discrete components such as the rotor, stator, outer frame, and motor (motor).
First, the fan rotor section:
Including the fan blades, which are the core component responsible for generating airflow. The cooling fan shaft supports and balances the rotation of the fan blades, the rotor magnetic ring, and the permanent magnets, playing a crucial role in accelerating the magnetic pole switching process. The outer frame of the magnetic ring secures the magnetic ring in place.
Second, the stator section of the fan:
Includes support springs, a separate bearing for the balance shaft, bearings themselves, providing high-speed, low-friction, long-life rotation; retaining rings; fixed nodules for rotating the entire assembly; motor components; and key factors determining the direction and speed of rotation.
3. Cooling fan frame:
Supports the fan motor and directs airflow.
Fourth, the fan motor section.
It includes a circuit board that controls energy consumption and the flow of signals in and out; silicon steel plates (i.e., stator magnets and upper winding coils) generate magnetic poles for propulsion switching; and silicon steel plates with upper and lower covers secure insulators.
② Basic knowledge of cooling fans.
First, fan size:
Fan dimensions are typically indicated by the fan’s external length and product thickness, with units in millimeters (mm). Fan specifications and models are usually named based on their dimensions. For example, in AD6010, “6010” refers to 60 mm × 60 mm × 10 mm.
2. Rated Voltage: This is the voltage value at which the fan is designed to operate under rated conditions. Common DC fan voltages typically include 5V, 12V, 24V, and 48V, among others.
Third, fan speed: The fan’s rotational speed, measured in rpm (revolutions per minute), is an important parameter of the fan. It determines the fan’s ability to generate high airflow at high speeds. Manufacturers often standardize their products into different categories—ultra-high (U), high (H), medium (M), and low (L)—to allow users to choose according to their specific needs.
Fourth, airflow: a quantitative indicator of fan performance. The unit is cubic feet per minute (CFM); however, in some regions, the unit is indicated as cubic meters per minute (CMM), where 1 CMM equals 35.31 CFM.
Fifth, wind pressure: the ability of a vehicle’s aerodynamic design to overcome air resistance. It directly affects ventilation or cooling performance and is measured in mm-H₂O; in some regions, the unit is indicated as inH₂O. 1 mm-H₂O = 0.03939 inH₂O.
Sixth, the noise level is an important parameter. Its unit is DBA (decibels). Although it is unrelated to ventilation and heat dissipation performance, it places high demands on usage in different environments.
7. Bearing System: This component is the heart of the fan and directly affects the product’s mechanical service life. It typically comes in two types: ball bearings and oil-lubricated bearings.
Eighth, the connector: an important detail on the fan, commonly categorized as endless, 2P, 3P, and large 4P, among others.
③ DC brushless fan circuit.
Micro DC motors are widely used in household appliances, especially in computers. This new type of DC fan features a brushless design, overcoming the drawbacks of traditional commutator (brush) motors, such as easy wear, high noise levels, and short service life. Several fan circuits drawn based on actual devices are shown below.
④ Principle of brushless DC fans.
The pulse generator based on Hall elements features a simple structure and excellent performance. Given the harsh electromagnetic environment of locomotive electrical systems, the product itself must possess strong anti-interference capabilities.
The brushless DC fan is driven by a brushless motor, which produces no electromagnetic interference. It completely overcomes the drawbacks of electromagnetic interference, high noise levels, and short mechanical lifespan, making it widely used in applications in the electronics and electrical engineering fields that require forced cooling.
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