Imagine having a USB charger that not only provides a steady voltage but also offers a high current output for your projects. Well, that’s exactly what I’ve been searching for, and in this article, I’ll share with you my findings and the solutions I’ve come up with.
The Problem with Battery Chargers
Many battery chargers in the market, particularly those based on the TP4056 IC, have a current output limitation of 2 amps. This can be insufficient for projects that require more power. Additionally, what if you need to charge multiple batteries connected in series using a USB connector? That’s another challenge.
The Ideal Solution
So, what do we need in an ideal charger? We want a charger that is easy to use with a USB 5V input, a TP4056 IC to charge the battery to 4.2V, and undervoltage protection. To achieve a high current output, we can combine the TP4056 with a dedicated Battery Management System (BMS) designed for the specific number of cells in our battery pack.
Exploring Different Modules
While searching for the perfect solution, I stumbled upon various modules available on the market. I found one with a USB Type-C connector that had a current output of 3.1 amps, which was better but still not ideal for my projects. There were also modules that could only charge the battery or lacked protection altogether.
Customizing the Charging Module
To address the limitations of the TP4056-based charger, I decided to modify it. By replacing the MOSFETs with ones capable of withstanding up to 10 amps, I could increase the current output. I designed a schematic and PCB layout to incorporate these changes, allowing for a higher current output while maintaining the desired voltage control and protection.
Taking Charge of Battery Protection
To protect the battery during charging and discharging, I connected the TP4056 module to a 1S BMS. This BMS, designed for a single-cell battery, offered overvoltage and undervoltage protection with a maximum current output of 10 amps. This configuration provided the ideal combination of voltage control, protection, and high current output for my projects.
Expand Your Power Options
What if you need to power a battery pack with multiple cells, such as a 2S, 3S, or more? In such cases, using a balanced BMS connected to the middle point between the batteries becomes necessary. However, the TP4056-based charger with its 4.2V maximum output voltage is no longer suitable. To overcome this, I discovered a module with a different driver and a boost converter that could elevate the voltage to the desired level, such as 8.4V for a 2S pack.
The All-in-One Solution
To simplify the setup further, I envisioned an all-in-one PCB that combined the boost converter and BMS, along with the charger and USB connector. This would allow for a single device that delivers both a USB charger and a high current output, making it incredibly convenient for a range of projects.
In summary, I’ve explored various options to overcome the limitations of traditional battery chargers. By combining the TP4056 IC with a dedicated BMS and making some modifications, I have achieved the perfect combination of a USB charger with a high current output. This solution offers both convenience and flexibility for a wide range of projects.
Stay tuned for my upcoming tutorials on BMSs, boost converters, and when to use different types of modules. If you want to dive deeper into this topic, check out my website, Banking Blog, for more information. Feel free to leave a comment or like if you found this article helpful. Until next time, happy charging!