Mini Table Fan

I wanted to purchase a mini fan for my mom while working in kitchen. Searched in the internet and found battery operated mini fans but air flow is very less. So I decided to make my own and came up with 2 approaches.

1. DC powered fan
2. AC powered fan

With DC powered fan, lot of circuit needs to be made (AC to DC converter, DC Step down, Speed control) and the DC motor heats up quickly. need to manage the heating issue, noisy, easy wear and tear.

With AC powered fan, less circuit or only speed control (optional) is required. AC fan doesn't heats up quickly and can be run for long time, less noise, less wear and tear.

I decided to make my own design using Panel cooling fan which has good airflow.

Note: Since this mini fan is powered with AC (high voltage) please be cautious while working.

• M5 Bolt 35mm - 1pc
• M5 lock nut - 1pc
• M5 Bolt 10mm - 4pcs
• M4 Bolt 55mm - 2pcs
• M4 Bolt 20mm - 2pcs
• M4 lock nut - 4pcs
• M3 Bolt 50mm - 1pc
• M3 Bolt 30mm - 2pcs
• Panel Cooling Fan (120 x 120 x 38mm) AC - 1pc
• BT136 - 1pc
• 500k potentiometer - 1pc
• 10k resistor - 1pc
• 0.1uF 400v - 1pc
• DB3 Diac - 1pc
• AC power cord - 1pc
• Perf board - 1pc
• Zip tie - 1pc
• Plastic mesh
• 3d printed parts

Download stl files from printables.com

• Base - 1pc
• Electronics Cover - 1pc
• Air Guard - 1pc
• Tilt control - 1pc
• Back cover 1 - 1pc
• Back cover 2 - 1pc
• Handle - 1pc
• Handle spacer - 4pcs
• Tilt Knob - 1pc
• Tilt knob stopper - 1pc
• Speed Control knob - 1pc

Insert two M3 screws inside Tilt control part as shown in pictures to give the part more strength.

Combine Tilt control and Air guard parts with four M5 screws.

Insert M3 screw to Tilt Knob to give extra strength. This part is responsible for vertical alignment.

Assemble the body by combining Top and Base parts as shown in pictures. Place Tilt knob between two parts.

Place plastic mesh between back cover 1 and Back Cover 2 and apply glue.

Assemble the Fan with 2 M4 long screws and 2 M4 short screws at the bottom. Add Handle and back cover in the process. Do not miss to add handle spacers.

https://www.hackatronic.com/circuit-of-fan-regulator-based-on-triac-and-capacitor/

I have used the circuit which is available in above website. This is to control the fan speed. Circuit is made in perf board and pushed the circuit in base print. Added zip tie to power cord in order to prevent the wire to come out. Close the cover as shown in picture. Insert Speed control knob. 500k potentiometer is prone to electric shock, covered with speed control knob.

Note: Working with high voltage is dangerous. Power ON/OFF switch was not added in the design, please work carefully.

Finally mini table fan is ready to use.