Predictive Thermal Management for Dual PWM Fans in High-Power Audio Amplifiers

This paper presents the design and implementation of a low-cost microcontroller-based dual-channel fan controller optimized for high-power audio amplifiers, yet adaptable to power supplies, electronic loads, and other thermally intensive systems. Unlike conventional designs that drive all fans uniformly, the proposed solution provides fully independent cooling via dual I2C temperature sensors, predictive trend analysis, and multi-stage hysteresis. The controller incorporates advanced features including an anti-dust startup sequence, predictive boost with latching, active cross-cooling, anti-heat-soak protection, and stall detection via tachometer monitoring, complemented by LED-based fault signaling and automatic channel muting during overheating or fan failure. Hardware support for 12 V and 24 V fans, dual power-input options, and a compact PCB layout enhance integration flexibility. The firmware employs temperature-driven PWM mapping with EMA filtering and multi-level hysteresis. The experimental results confirm that all implemented features operate as intended, with each function demonstrating clear practical relevance, whether in improving responsiveness, preventing heat accumulation, or enhancing system reliability under a wide range of operating conditions.