Electronic – Using a 4-pin computer fan controller without the load

Brief background: The tachometer output comes from a Hall-effect sensor mounted on the motor driver PCB on the fan frame. One or more magnets embedded in the fan rotor hub activate the Hall-effect sensor as they pass by. The sensor is amplified, and eventually drives a logic circuit. The fans that I have seen use an open drain/open collector output.

One (or more) pulse is generated every time the the fan rotor completes a revolution. The number of pulses counted in one minute is directly proportional to the RPM of the fan. In your fan's case, I think it would be reasonable to guess that there are two pulses generated for each revolution. With the frequency that you have measured, about 1500 RPM sounds right, given that you are running it at 10V (12V nominal) and the typical is 1800-2000 RPM.

If you want a more visual approach, you can make a crude strobe tachometer using just a LED and resistor. Connect a LED (brighter is better) and an appropriate current-limiting resistor between power and the tachometer pin. If you mark one of the fan blades with something easy to see, like a sticker, you should be able to shine the LED on the fan blades and see the sticker illuminated in two places. You can use this technique to count the number of times the tachometer output goes low each rotation, and to approximate the duty cycle of the signal.

While the statement that "any DC motor can be driven with PWM" is broadly correct* if the actual motor is PWM controlled, in a given implementation the motor proper may be hidden behind an internal controller, and this the case for the very large majority of devices that use small BLDCMs (Brushless DC motors).

Most small modern fans use BLDCM's.
In a BLDCM the motor speed is notionally independant of applied voltage. A range of voltages will be requied to operate correctly but within that range the voltage will have either essentially no effect on motor speed or a second order one.

If a system uses PWM to control an external motor's speed, special attention will be required to translate the speed control signal into actual control of speed. A BLDCM usually uses magnetic sensors ** (usually Hall sensors) to determine rotor position and to switch voltages appropriately. The electronics may be as simple as the sensors but more usually there is a control IC. If voltage is changed the controller will usually attempt to oppose any change and maintain constant speed. A PWM signal or a DC level could be used as a signal to a controller re appropriate speed.

• Some DC motors are not overly keen on being PWM'd due to interesting arrangements of field coils. While small brushed DC motors in consumer equipment may use permanent magnets, larger motors tend to have wound rotors and may have fields in series ("Universal motor" as in vacuum cleaners - revs unto death if unloaded), parallel or some compound arrangement. Consultation of dry and dusty tomes and manufacturers' spec sheets recommended if ever considering PWMing "real" motors.

• ** Some controllers determine rotor position from back-emf on windings and other esoteric schemes may exist. Hall sensors seem to be a common solution.