Intelligent Motion Controls HVAC | Pelonis Tech

Posted by Sam Pelonis | May 10, 2019 2:13:52 PM | 0 Comments

Brushless DC fans and blowers need optimal motion control. When complex or demanding applications need precise levels of output, intelligent motion control systems can keep parts safe while still ensuring high-quality production cycles. These intelligent motion controls (IMCs) have in-board circuits that use programmable, information-gathering features to develop air movement “intelligence” and learn how the parts need to operate in different environments.

IMCs are ideal for:

  • Green applications in which facility managers want to improve reliability, the equipment’s life expectancy, and energy efficiency.
  • Systems that need consistent monitoring and cooling—IMCs have multi-alarm connections to prevent complete system failures, reduce voltage fluctuations, and have more reliable control.

When businesses install IMCs, they will make their facilities greener and more efficient. Read on to learn about all the different benefits IMCs can bring.

Top Solutions

There are several different types of IMCs that can add control to the operation and maintenance of brushless DC fans and blowers. The top four IMC solutions are:

Rotation Detectors

A smart rotation detector can monitor fan operations in parallel circuits to detect ongoing circulation as well as potential failures or stopped fans. These systems give a “high” output signal to the monitoring interface while the fan rotates. That same signal turns to “low” or “off” based on the fan’s status. This allows operators and maintenance teams to investigate potential problem areas more quickly because the system automatically notifies them when a fan stops working rather than requiring them to monitor changes in temperature.

Rotation detectors use the same hardware as the frequency generator (tachometer), which we also describe below. Once the detector is added to an array of fans, it operates as part of the facility’s multi-alarm connection.

Rotation Detectors

Inrush Current Protection

When motors, heating elements, transformers, and power supplies turn on, the current surges. This short-lived inrush current can damage electronic parts if it isn’t properly controlled.

Facility managers use inrush current protection to slow the flood of current to the equipment. This technology allows fan blades to speed up at a more gradual rate through incremental increases of current. The process takes approximately ten seconds during startup, and it protects both the circuits and the moving parts from damage.

Inrush Current Protection

Auto Start

Sometimes, fan blades get blocked by temporary obstructions. Auto starts control the current output in these circumstances. First, the current can be reduced to zero when an obstruction is detected so the fan blades don’t damage themselves. This feature is called locked rotor protection. Then, the auto-start control uses a second feature, restart with current limit, to guarantee the restart of the rotor once it is released.

Auto Start

Frequency Generator (Tachometer)

This IMC solution is an open collective output type that produces an analog voltage based on the fan’s motor speed. These parts provide feedback and can be used to measure the speed of motors, rotors, and engines.

Frequency generators use the same hardware as rotation detectors, and they’re powered by the power supply voltage. A tachometer will send a square wave signal to the reading device if the collector connects with a pullup resistor. This part can handle a maximum collector voltage of 72 V DC and current of 10 mA.

Frequency Generator

Quality IMC Solutions from Pelonis Technologies, Inc.

Smart IMC solutions keep your equipment’s DC blowers and fans operating at their full potential. These tools also extend the lifespan of your equipment and protect electronics from the dangers of overheating.

Pelonis Technologies, Inc., provides a wide array of fans, blowers, and other cooling and heating solutions. Contact our team to learn about our customization services or to browse our design catalog.


Industrial Cooling Fan System Applications | Pelonis Tech

Posted by Sam Pelonis | Apr 15, 2014 12:14:23 PM | 2 Comments

The question of how to provide the best cooling for industrial applications has been around since the earliest days of the industrial revolution.  When equipment is functioning at a high level, it often produces heat that needs to be dissipated, and today, facilities are using systems that are more advanced than ever. 

With the advances in technology that are so commonplace in today’s industrial landscape, many systems are being designed to provide the greatest power possible in the smallest possible space.  These systems can run the risk of overheating if they are not designed with an appropriate cooling mechanism. 

Overheated equipment can pose many risks, including poor performance of equipment, early component and lubricant deterioration, overall system malfunction, and ultimately the possibility of fire and other safety risks for users and operating personnel. 

pelonisIn order to avoid these problems, design engineers need to select the appropriate cooling unit for these systems.  One popular and economical option is the use of cooling fans.  Cooling fans are available in a wide array of options according to the temperature needs of the project.  Some considerations that a designer needs to think about when choosing the best cooling application include the size of the unit, voltage, and how much noise is involved.        

Different Sizes for Different Applications

Just as mechanical systems can come in all different sizes, the dimensions of cooling fans also vary greatly in order to ensure the best temperature stability.  This process is usually begun by thermal analysis, which is used to ascertain how much heat is generated inside systems in order to find out how much cooling is necessary. 

After this has been determined, a design engineer can then choose the proper sized cooling unit.  The exact size needed can be determined according to the sizing and density of the individual application.  For instance, cooling units for computers often need to be placed in very small spaces, and therefore will need to be designed to run at a high speed. 

By calculating the space available and how much cooling is needed, the appropriate fan can be chosen or designed as needed.  Knowing the desired temperature is also necessary for choosing a fan for large scale applications.  Larger fans can be used in applications such as locomotive engines that need a large volume of air constantly blowing to keep the engine and engine fluids cool. 

Fans of this size are not only used to keep equipment cool, but also to maintain comfortable temperatures for personnel working in industrial environments.  Cooling fans for HVAC systems can ensure that all workers are safe and comfortable, and usually are required on a large scale.

High or Low Voltage

blogThe power supply used for a fan will influence its size and many other aspects of its operation, and must be taken into consideration when choosing the best cooling system.  The voltage that a fan requires will be dependent on its size and speed.   The parameters that best represent the voltage needed can be found in a fan performance curve. 

A performance curve graphically represents a variety of parameters that relate to the construction of fans.  These include the fan space, static pressure, airflow quantity variation, and required current for any specific fan voltage.  This tool is essential for design engineers to pick fans that have the correct voltage to cool systems sufficiently. 

Certain models, such as DC fans, are built directly proportionate to voltage, making them highly efficient in regard to energy consumption.  These models can also be designed with circuits that reduce voltage spikes in operation, providing efficient and smooth cooling results.


There are many different factors that can influence the noise level associated with fan operation.  The amount of noise that comes from a fan is determined in part by how big the fan is and how fast it spins.  Essentially, the faster a fan operates the more noise it produces. 

A larger fan running at lower speeds can produce the same energy with less noise than a smaller fan running at a high speed.  However, these types of size adjustments are not always practical, depending on the size requirements of the design engineer’s specific application.  The type of fan employed also affects the amount of noise generated.  The two primary types of industrial fans are axial and centrifugal, and they vary when it comes to noise. 

Axial fans work similarly to an airplane propeller, and while they tend to be compact, inexpensive, and light, they are noisier than centrifugal fans.  When noise is a concern, alterations can be made to fans, and these include insulation of the duct, installing material that dampens sound, or mounting the fan using soft materials such as rubber. 

Some noise will be inevitable when operating fans, but certain fan types, installation options, and designs can minimize noise as much as possible.

Many Determining Factors

For buyers and designers in the market for cooling systems, the above factors represent some of the major concerns associated with acquiring fans.  There are other aspects to consider as well.  The exact sources of heat, fan performance, reliability, and cost all need to be taken into account. 

When determined early in the system design process, the correct cooling system will help keep hardware and personnel safe while increasing the longevity of important equipment.  By acquiring high quality cooling fans, buyers and designers can easily ensure that even the most advanced, dense, and heat generating equipment can be operated with the utmost safety and efficiency.       

Download How to Select a Cooling Fan



DC Brushless Fans & Blowers Automation | Pelonis Tech

Posted by Sam Pelonis | Jan 6, 2014 9:00:00 AM | 0 Comments

Automation is now a buzz word and hot technology trend in both the consumer and manufacturing worlds, so it is interesting to consider how various motion controls would work in a fully integrated and automated society. 

To what degree could every aspect of a home’s HVAC and appliances be operated via intelligent controls, and to what extent could a manufacturing environment be controlled by smart automation?

blogThe use of Intelligent Motion Controls in DC brushless fans and blowers has already arrived.  With Intelligent Motion Controls, the movement of air is now smarter. 

The inclusion of full-wave-in-board circuit design and multiple features leaves no doubt that intelligence has enhanced air movement.

A few Intelligent Motion Control features for DC brushless fans and blowers include:

  • Inrush Current Protection – Allows the power to be turned on to supply current to the fan.  The current begins at zero and gradually increases until the fan reaches its maximum speed and rated current.
  • Auto Start – An intelligent motion control ensures that if a fan’s blade is blocked and released, the fan will automatically restart.
  • DC Voltage Signal Control – The DC Voltage Signal Control (VPWM) controls the speed by applying an external DC voltage signal.
  • Automatic Temperature Control – When the Automatic Temperature Control is applied, the upper and lower temperatures may be selected, as well as the choice of maintaining a minimum RPM below the minimum temperature chosen.

These are only a small sampling of the features that Intelligent Motion Controls provide to fans and blowers.  You can learn more about Intelligent Motion Controls in DC brushless fans and blowers by downloading our free eBook. 

Just click on the button below to access your free copy, and if you have any questions, please give us a call or send us an email.  We are happy to hear from you and look forward to working together on your next project.

Download Our Free Intelligent Motion Controls eBook