FORM NO 2
THE PATENTS ACT, 1970
(39 OF 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
[See sections 10 and Rule 13]

1. TITLE FAN REGULATOR WITH 9 STEP ROTARY SWITCH

2. APPLICANT(S) NOVATEUR ELECTRICAL & DIGITAL SYSTEMS PRIVATE LIMITED
61/62, 6th Floor, Kalpataru Square, Kondivita Road, Off Andheri - Kurla Road, Andheri (East) Mumbai -400059
India
3. PREAMBLE TO TH E DESCRITION
COMPLETE
The following specification particularly describes the invention and the manner in which it is to be performed

TITLE
FAN REGULATOR WITH 9 STEP ROTARY SWITCH
FIELD OF INVENTION
The invention relates to a 9 steps Rotary Switch used for fan regulator with three parts (1) The base ( 2) The Shaft (3) The Top cover enabling 9 variable speed steps including OFF (Zero) Speed Step.
BACKGROUND AND PRIOR ART
Ceiling fans are commonly 3 blades or 4 blade electrical appliances used for moving/circulating the air in a room so as to comfort the user. To adhere to different external atmospheric conditions and air delivery requirements by user, it becomes necessary to control the speed of ceiling fan so that the user has option to choose the desired fan speed. Controlling of the ceiling fan speed is done by a special device called as "Fan regulator". A Fan regulator allows the user to control the speed of ceiling fan to desired speed which suits his comfort. Below is typical figure showing Fan regulator connection with a ceiling fan.

Fan regulator
Phase
ACtnput supply


Ceilingfan

Neutral
Today, the common types of fan regulators are a) Resistive type, b) Inductive type, 3) Electronic solid state type, 4) Electronic capacitive type. Of these Resistive and Inductive type are now

outdated and solid state type is used only for light dimming option. Capacitive type fan regulators are more popular and used because of their compact size, power saving capability and noise free operation.
The existing fan regulators in use today are mainly of capacitive type and are in 4+OFF or 5 +OFF number of variable speed steps. The speed steps are achieved by a specific value of electrical capacitance applied electrically in series with the ceiling fan electrical motor load. The existing fan regulators have certain limitation to give good speed regulation for the user. The limitations being, the speed of fan at different steps will not be the same for different makes/models due to the internal fan motor design characteristics, fan blade design, fan weight etc., of the fan. This leads to improper speed regulation of the ceiling fan and user dissatisfaction, as he is not able to control the speed of fan at desired level. Due to this limitation the existing fan regulators fail to achieve complete user satisfaction.
The present Invention is an attempt to provide for 9 step fan regulator, which overcomes the limitations of existing 4 /5 speed step design and improves the speed regulation by giving the user increased number of speed steps. The new fan regulator design involves 8 number of variable speed steps and in addition an OFF (zero) speed step.
OBJECT OF THE INVENTION
It is the object of invention to provide for 9 steps Fan regulator and its design, with more speed control and speed steps adjustment with most of ceiling fans of different makes and for sizes 1200 mm and 1400mm sweep, due to more number of speed steps spread over.
Detailed description and working of New 9 steps Fan regulator.
The Invention can be better illustrated with references to the accompanying drawings Figure A (comprising of parts of the Rotary Switch) Figure B (functioning of the Switch).
The 9 step fan regulator has an inbuilt electronic mechanism - a PCB assembly comprising of electronic/electrical components as below...
a) Four AC capacitors of different values
- Used for controlling the current to Fan motor by putting different capacitor values in the
circuit with the fan motor. The different values of capacitance at each step are achieved by
capacitors electrically connected in different combinations with help of rotary switch which
varies in each step.
b) A nine Step rotary switch with three contact wipers.
- This is a nine step rotary switch with 13 fixed contacts (centre A+12 circular contacts) and
three moving contacts also called as wipers. In this rotary switch at all step, three fixed contacts
are connected electrically together. The contacts are connected in the pattern of two alternate

and third contact is 2nd contact after the earlier two contacts in terms of count. Example at 4th step it is 1+2+4, 5th step is 5+2+3 and so on.
c) Four wire wound resisters
- These resistances are connected in series with each capacitor and are required for
suppression of the surge current during switch over of motor from one speed to another and
thereby decreasing the contact sparking during switch step change.
d) Four carbon film resisters
- These resisters are connected electrically in parallel with each capacitor, so as to discharge
them when not in the active circuit. There by avoiding shock hazard.
e) One PCB of specific size
- PCB's are glass epoxy type for making an electrical assembly as per the circuit diagram with
the components and achieve the desired electrical performance of the circuit.
In the new rotary switch used for making the Nine (Off + 8) step fan regulator there are three moving wiper contacts which are connected to the moving shaft of the switch and are used for achieving different electrical combinations with the four incorporated capacitors at each step and thus achieving different fan speeds.
The rotary switch has three parts 1) The base (Fig: B), 2) The shaft (Fig: A), 3) The top cover (Fig: A).
The wiper contacts are fixed on the moving shaft and act as electrical connection bridges between the different fixed contacts which are fixed on the base to which the different values of capacitors are connected (with the help of PCB).

By incorporating three wiper contacts it becomes possible to connect three capacitors at a time and thus achieve a bigger value of total capacitance as well as get more capacitor combinations required to achieve 8 speed steps with use of only four capacitors. This is very important as it is required to achieve the desired results with size constraint (limited number of capacitors).
Electrical connections: Each of the wiper contacts has two arms, one arm of each contact is always in electrical connection with Fixed contact "A"(see Fig B) and other arm of each contact connects to different fixed contacts out of total 12 contacts which are fixed on the base (see Fig B). So when the switch shaft is rotated in steps the arm of the wiper contact slides from one fixed contact to another thus changing the capacitor combinations.
Capacitors play the main role to achieve different speeds of Ceiling Fan by incorporating different impedance (electrical resistance) in the electrical circuit thus controlling the amount of current to the Fan motor at each speed steps.
The other main task to be considered when designing a fan regulator, so that it is well accepted by the customers is selecting specific capacitor values used in the regulator so as at all steps when different capacitors combinations happen with the help of rotary switch, it shall give a desirable speed of fan. Thus the capacitor values are very important, in this new fan regulator the capacitors selected are 0.6=C1, 3.6=C2, 0.8=C3 and 2=C4 microfarads. The combination of the capacitors at each step gives a specific capacitance value and helps to get particular speed values for the fan connected to it. (See Fig C) These capacitor values satisfies two important factors of Fan regulator performance
1) The speed increases in ascending manner as we rotate the switch from 1 to 8 and vice versa, (see Fig: C)
2) The speed regulation is better as compared to existing 4 step or 5 step fan regulators in use. This means the difference between consecutive steps is less and user can have more fine speed adjustment than existing fan regulator. See (Fig D) where a regular 5 step existing fan regulator capacitor values are compared with 8 step fan regulator.

Step position (A) The contacts connected by the rotary switch (B) Capacitors connected in the circuit (C) Remarks (D)
OFF 12, 10,9 Nil Zero Speed/Zero voltage to Fan
1 1, 11, 10 C4

2 2,12,11 C1+C4

3 34,12 C2

4 4,2,1 C2+C1

5 5,3,2 C3+C2+C1

6 6,4,3 C4+C2

7 7,5,4 C4+C3+C2
8 8,6,5 Regulator Short circuit. Full speed/ Full voltage to Fan
Fig:C
For Nine steps ( 8 + off) the resultant capacitor value in the circuit will be as below...
Step 0 (0mf) ->Step l(2mf) ->Step 2 (2.6mf) -> Step 3(3.6mf) -> Step 4(4.2mf) •> Step 5(5mf) ->Step 6(5.6mj) ->Step 7(6.4mJ) -> Step 8(short circuit)
(# mf-> microfarad)
For a regular 6 step(5 + Off) Fan regulator the resultant capacitor value in the circuit is...
Step 0 (Omf)->Step l(2.2mf) -> Step 2 (3.4mf) -> Step 3(4.4mf) -> Step 4(5.6mJ) ->Step 5(short circuit)
(# mf-> microfarad)
Speed gap is more

Fig:D
Above Fig D, is an example of a plot of 5 step+Off fan regulator v/s 8 step+Off fan regulator. It indicates the improved speed regulation of 8+OFF steps fan regulator.

The other important component is the PCB (printed circuit board) which is also used in the existing fan regulators; difference about new 9 step fan regulator is the electrical layout design on the pcb. This lay out or the connection tracks are designed in such a way that it makes it possible to connect the four capacitors, rotary switch, eight resisters as per the electrical circuit diagram. This makes it possible to get the desired electrical output with each turn of the rotary switch. The circuit diagram for 9 step fan regulator is shown in Fig. E.
Also, to facilitate the engagement of the wires for electrical connection, the fan regulator is provided with connecting wires or terminals (similar existing fan regulator)


240VAC , SO Hz
Input Power

R4,R3,R2,R1 = Wire wound resisters R8,R7,R6,R5= Carbon film resisters C1,C2,C3,C4= AC Capacitors of different values

SW1=Rotary switch

Fig : E (Circuit diagram 9 step fan regulator)

As seen in the circuit diagram-
a) The four series wire wound resisters R4,R3,R2,R1 of value (value=3.3 Ohms) are the same as used in existing fan regulators which are used for limiting the current during step change over.
b) The discharge Carbon film resisters -R8,R7,R6,R5 resisters (value=390K Ohms) are the same as used in existing fan regulators which are used for discharging the capacitors when not in use.
This new 9 (8+ off) steps fan regulator promises to give better speed regulation as compared to
existing 6 step (5+off) fan regulator.
The speed regulation improvement is due to the decreased speed (RPM) difference between
consecutive steps compared to existing 5 steps Fan regulator.
As can be seen in the Fig D above the user can get finer speed setting as desired compared to 6
steps fan regulator. See Fig D.
Since the new fan regulator introduces 3 additional steps as compared to existing and the maximum speed to fan remains the same (same speed value for new and existing fan regulators at last step) there is no additional power consumption by use of the new 9 step fan regulator.

WE CLAIM :-
1) A 9 steps fan regulator with an inbuilt electronic mechanism that is a PCB
assembly comprising of-
• Four AC capacitors of different values
• A 9 steps rotary switch with 3 contact wipers
• Four wire wound resisters
• Four carbon film resisters and its integrated design with more speed control for most types of ceiling fans, which are of sizes 1200mm, 1400mm sweep.

2) A 9 step fan regulator as claimed in claims 1 above which comprises of four AC capacitors of different values in circuit with a fan motor.
3) A 9 step fan regulator as claimed in claims 1 and 2 above which has a rotary switch with 3 contact wipers wherein one contact of each wiper contacts are connected electrically together.
4) A 9 step fan regulator as claimed in claims 1 to 3 above which has a four wire wound resister to regulate current during the use.
5) A 9 step regulator as claimed in claims 1 to 4 above which includes a four carbon film resister to avoid shock hazard.
6) A 9 step fan regulator as claimed in claims 1 to 5 above which includes a PCB(printed circuit board) of glass epoxy type compatible to electrical assembly to achieve desired electrical performance of the circuit.
7) A design and assembly of a 9 step fan regulator as described with accompanying specifications.