How Do You Monitor the Health of Your Fan?
In the aerospace and defense sectors, we rely on a network of linked and interdependent electronic systems working together to enable the crew to do their jobs. These systems provide situational awareness, communication, navigation, flight/vehicle controls and a multitude of other essential inputs and actions – and each one is based on electronic components operating reliably via a thermally controlled environment. In many cases, fan cooling is employed to create that thermally controlled environment, making the fan an essential element. So, what happens if the fan no longer provides the necessary cooling?
Given the significance of thermal management, cooling fans are typically equipped with a health output signal such as Rotron’s Fan Performance Sensors (FPS) to provide a status signal to the system that is being cooled. The FPS outputs a simple tachometer type signal, providing real-time information about rotation fan speed (and resulting airflow disruptions) in a case where the system has been designed to monitor and act on this type of signal. For systems that do not incorporate a fan signal processing capability, Rotron’s Low-Speed Warning Detector (LSWD) can serve to provide a discrete fan health signal.
A LSWD acts as a first line of defense, providing early warnings against potential fan failure. When paired with FPS, it ensures that any deviation is quickly detected, allowing operators to address the issue before it escalates.
Figure 1: A Low-Speed Warning Device
How do these systems work?
Most of Rotron’s fans are equipped with an internal FPS. This health monitoring function is based on the incorporation of a Hall Effect device that produces a signal level waveform in a tachometer style output (Figure 2). For DC fans, the FPS output is powered via the standard power inputs to the fan. For AC fans, a secondary low power DC power source is required to enable the operation of the FPS function.
A LSWD (Low-Speed Warning Detector, Figure 1) is designed to use the FPS output of the fan and interpret that signal to yield a discrete indication for potential fan failure in the near future. Each LSWD device is matched with a particular fan operation speed and is configured to provide a warning signal including visual status (LED on/off), discrete signal output via a 5VDC line or pin, or any similar system output requirements, catering to the specific needs of the system.
"A LSWD acts as a first line of defense, providing early warnings against potential fan failure. When paired with FPS, it ensures that any deviation is quickly detected, allowing operators to address the issue before it escalates."
Figure 2: An example of the FPS tachometer type output.
Why Choose Rotron's Solutions Over Alternatives?
Reliability is at the core of Rotron's products. Using our solutions can extend the lifespan of units, reduce replacement frequency, and possibly save significant costs. For instance, early detection of a low-speed condition might need a simple bearing replacement as opposed to replacing an entire unit if the issue goes unaddressed.
Rotron’s solutions stand out with their customization capabilities. Not only can an FPS be added to any unit from our catalog, but we also offer unique design flexibility to meet diverse applications. Rotron has expertise in integrating Fan Health Monitoring Systems within fan electronics. For situations where an internal monitoring system isn't feasible, we can craft external modules tailored to specific performance requirements.
The versatility in size and power options that Rotron offers makes these features an essential part of cooling systems. Especially for systems deep into their design phase, the promise of reliability is a critical consideration.
Rotron's solutions have found their place in diverse settings including:
- Avionics Equipment
- Communication Equipment
- Radar Systems
- Signal Processors
- Power conversion and distribution
If you would like to see how Rotron’s fan monitoring systems can be implemented into your systems, get in touch with us today.
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