248 lines
9.5 KiB
Markdown
248 lines
9.5 KiB
Markdown
# Battery-Powered 28BYJ-48 Stepper Controller
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This project uses one 18650 cell, a TP4056 charger module, an MT3608 boost
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converter, an Arduino Nano, and a ULN2003 driver board to power a 28BYJ-48
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stepper motor.
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A single-pole KCD11 rocker switch turns the battery-to-boost path on and off.
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Turning the switch off removes the boost input, so the whole 5 V rail (Nano and
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motor) is unpowered. The Arduino Nano clone used here has **no USB VBUS Schottky
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diode**, so the USB and battery-powered 5 V supply must not be connected to the
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Nano at the same time.
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> This document describes wiring and power only. It does not include Arduino
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> code.
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---
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## 1. Components
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| Component | Notes |
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| 18650 Li-ion cell | Single cell, suitable holder or secure battery connection |
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| TP4056 charger module | Use a protected module with separate `B+`, `B−`, `OUT+`, and `OUT−` terminals |
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| MT3608 boost converter | Adjustable; set its output to 5.0 V before connecting the loads |
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| KCD11 rocker switch | Single pole, on/off; see the variant note below |
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| Arduino Nano clone | This clone has no VBUS Schottky diode |
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| 28BYJ-48 stepper motor | Use the 5 V version |
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| ULN2003 driver board | Matches the motor’s 5-pin plug |
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| Optional fuse | Near TP4056 `OUT+`; rated above normal load current and below safe limits of the cell, protection board, and wiring |
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| Optional capacitor | 100–470 µF across the 5 V rail; observe capacitor polarity and voltage rating |
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Check the labels on the actual modules: board layouts and terminal names vary.
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Some TP4056 boards do not have a protection circuit or separate `OUT` terminals.
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This diagram requires a protected module with separate load terminals. Do not
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assume an unprotected TP4056 board provides battery over-discharge or
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over-current protection, and do not use its `B+`/`B−` pads as though they were
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protected `OUT+`/`OUT−` pads.
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### KCD11 switch variants
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The KCD11 family ships in several contact configurations and often shares one
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housing across them. Terminals labeled `1`, `1a`, and `1b` describe a single
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pole with two throws; the unused throw may be molded into the housing with no
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metal lug. This build needs only **one on/off pole with two usable terminals**.
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On the switch used here, `1` is the **center lug (common)** and `1b` is the
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populated throw; `1a` is an empty pocket and stays **unconnected**. Wire the two
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switch wires across `1` and `1b`. A mechanical contact has no polarity, so
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either wire may go to either lug.
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Confirm the switch with a multimeter before wiring: there should be continuity
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between `1` and `1b` when the rocker is on, and none when it is off. A single
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pole is sufficient because the motor has no independent supply of its own (see
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section 4).
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---
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## 2. Power flow
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```text
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18650 ──► TP4056 protected battery/load terminals
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│
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└── OUT+ ──► KCD11 ──► MT3608 ──► 5 V rail
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├── Nano 5V
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└── ULN2003 VCC
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```
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The TP4056 is a **charger**, not a 5 V power supply. Its `IN+`/`IN−` terminals
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are the USB charging input. The `B+`/`B−` terminals connect to the battery.
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The protected module’s `OUT+`/`OUT−` terminals provide the battery-voltage load
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connection.
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The MT3608 boosts the cell voltage (approximately 3.0–4.2 V) to 5.0 V.
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---
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## 3. Wiring schematic
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```text
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Battery:
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18650 (+) ──► TP4056 B+
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18650 (−) ──► TP4056 B−
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Charging input:
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USB 5 V (+) ──► TP4056 IN+
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USB GND ──► TP4056 IN−
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Battery-powered load path:
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TP4056 OUT+ ──[optional fuse]──► KCD11 terminal 1 (common, center lug)
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KCD11 terminal 1b ──► MT3608 IN+
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KCD11 terminal 1a (if present) ──► leave unconnected
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TP4056 OUT− ──► common system GND
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MT3608 IN− ──► common system GND
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MT3608 OUT− ──► common system GND
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Nano GND ──► common system GND
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ULN2003 GND ──► common system GND
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5 V and motor supply:
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MT3608 OUT+ ──► 5 V rail ──┬──► Arduino Nano 5V
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└──► ULN2003 VCC
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Control and motor:
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Arduino Nano D9 ──► ULN2003 IN1
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Arduino Nano D10 ──► ULN2003 IN2
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Arduino Nano D11 ──► ULN2003 IN3
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Arduino Nano D12 ──► ULN2003 IN4
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28BYJ-48 5-pin plug ──► ULN2003 motor connector
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```
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### Important TP4056 ground detail
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Connect the cell’s negative terminal to **`B−` only**. Connect system ground to
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**`OUT−`**. Do **not** add an external wire directly joining `B−` to `OUT−`;
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that can bypass the protection circuit on a protected TP4056 module.
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The battery negative and system ground may be connected internally through the
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module’s protection circuitry. Use the module’s labeled load terminals for the
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load.
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---
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## 4. KCD11 switch operation
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The KCD11 is a single-pole on/off switch in the battery-to-boost path, wired
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across terminals `1` (center common) and `1b`:
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- **ON (closed):** connects TP4056 `OUT+` to MT3608 `IN+`.
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- **OFF (open):** disconnects the battery from the boost input.
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| Switch state | Contact | Result |
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|---|---|---|
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| **ON** | Closed | Battery powers the MT3608; the 5 V rail feeds the Nano and ULN2003 |
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| **OFF** | Open | Boost input is disconnected; the 5 V rail (and therefore the motor) is unpowered |
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The ULN2003 `VCC` is tied directly to the 5 V rail, so there is no separate
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motor cutoff. The motor is unpowered whenever the switch is off because the
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whole rail is dead. The Nano can still be powered over USB while the switch is
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off; in that case the rail—and therefore ULN2003 `VCC`—is fed from USB. See the
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debug mode in section 6.
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---
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## 5. MT3608 setup
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The MT3608 is adjustable; it is not a fixed 5 V supply.
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1. Turn the KCD11 switch **OFF**.
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2. Leave the Nano and ULN2003 disconnected.
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3. Connect the cell and measure MT3608 `OUT+` to `OUT−`.
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4. Adjust the module’s potentiometer until the output is **5.0 V**.
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5. Power-cycle and recheck the output.
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6. Connect the Nano and ULN2003 only after confirming the voltage.
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The module’s current capability depends on its components, input voltage, and
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cooling. The MT3608 IC’s “2 A” switch-current rating does not mean every module
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can deliver 2 A at 5 V.
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---
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## 6. Operating modes
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### Run from battery
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- KCD11: **ON**
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- Nano USB: **unplugged**
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- TP4056 charging USB: **unplugged**
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The Nano and motor are powered from the MT3608’s 5 V output.
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### Charge the battery
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- KCD11: **OFF**
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- TP4056 USB input: connected to a 5 V charger
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- Nano USB: **unplugged**
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With the switch open, the battery-powered load path is disconnected. Keep the
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Nano USB unplugged during charging as the conservative procedure.
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### Debug over USB serial
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- KCD11: **OFF**
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- TP4056 charging USB: **unplugged**
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- Nano USB: connected to the computer
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- Disconnect the MT3608 `OUT+` wire from the 5 V rail while debugging.
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The Nano clone has no VBUS Schottky diode. Disconnecting the boost output during
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USB debugging avoids applying USB 5 V to the MT3608 output. With the switch open
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the boost is off, but the ULN2003 `VCC` still follows the 5 V rail, which USB now
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powers through the Nano’s 5 V pin. Hold the Nano in reset (or do not run the
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sketch) so the driver does not drive the motor from USB.
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**Never connect Nano USB while the KCD11 is ON.** In that state, the MT3608
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supplies the Nano’s 5 V pin, which could back-feed the computer’s USB port.
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---
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## 7. First power-on checklist
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1. Confirm the cell goes to TP4056 `B+` and `B−`.
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2. Confirm the circuit ground goes to TP4056 `OUT−`; do not bridge `B−` to
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`OUT−`.
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3. With the switch OFF and loads disconnected, set the MT3608 output to 5.0 V.
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4. Recheck polarity and wiring, including the KCD11 continuity check.
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5. Connect the Nano and ULN2003.
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6. Run from battery only with the switch ON and Nano USB unplugged.
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---
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## 8. Design notes
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- Use the Nano’s **`5V`** pin for the regulated 5 V rail. Do not use `VIN` for
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this 5 V supply.
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- The 28BYJ-48 plugs directly into the ULN2003 board; individual coil wires
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should not need to be jumpered.
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- Standard 28BYJ-48 ULN2003 boards do not have a current-adjustment trimmer.
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Leave their bypass capacitors installed.
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- An optional 100–470 µF capacitor can be placed across the 5 V rail and GND
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near the loads to help with supply dips. Observe its polarity.
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- Keep the Nano, MT3608, and ULN2003 grounds connected to the TP4056
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`OUT−`-referenced system ground.
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- The single KCD11 pole removes the whole 5 V rail when off, so there is no
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independent motor-supply cutoff. During USB debugging the rail and ULN2003
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`VCC` are fed from USB, so hold the Nano in reset and disconnect the MT3608
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`OUT+` wire.
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- Do not charge and run the load simultaneously with this simple TP4056
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arrangement. Supporting that requires a proper power-path/load-sharing
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design.
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---
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## 9. References
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These tutorials cover the stepper/driver portion of the project:
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- 28BYJ-48 + ULN2003 + Arduino walkthrough:
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https://lastminuteengineers.com/28byj48-stepper-motor-arduino-tutorial/
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- element14 stepper wiring walkthrough:
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https://community.element14.com/products/arduino/arduino-projects/b/blog/posts/how-to-control-28byj-48-stepper-motor-with-uln2003-driver-and-arduino
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TP4056 load-sharing background:
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- Arduino discussion of TP4056, boost converter, and Nano:
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https://forum.arduino.cc/t/using-li-ion-battery-with-tp4056-to-power-arduino-nano/1324112
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- TP4056 load-sharing modification discussion:
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https://forum.arduino.cc/t/tp4056-lithium-charger-module-modification-to-add-power-sharing/1008473
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