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How To Make Power Bank Circuit On PCB

Abstract

These days the digital products are being in immense demand. However, there are some products that you can make in your home with little things that you would get from the market. One of such product is the power bank circuit. The power bank circuit composition is very easy and can be made with little effort. There are numerous uses of the power bank circuit, for instance you can use it as a spare power bank in case when you need.

 

There are numerous ways through which you can make the power bank circuit e.g. one of the easiest way is to use a boost converter for making the power bank. However, one of other easy way to make the power bank circuit is by using different modules which can be used for the charging of the cell phone.

 

Content

1. A technique to make the Power Bank Circuit

2. The Main Components Required

3. Basic Circuit Diagram

4. Working of the main Circuitry

5. The PCB Design of the Circuitry of Power Bank

6. Etching, Drilling, and Soldering

 

1. A technique to make the Power Bank Circuit

 

This project is revolving with the making of the charging circuit from scratch. First of all the basic circuit schematics is being made which is then simulated. After debugging all the drawbacks of the circuit, its PCB is designed which is then etched and components are placed to make it working.

 

Power Bank Circuit on PCB1.png

 

 

2. The Main Components Required

 

The following is the list of main components required for the project.

 

  • PCB board.
  • IC of TP4056
  • XL 6009
  • Inductors (33uH)
  • Female connector (USB)
  • Charging pin (Female/Mini USB)
  • Burg stick
  • Capacitors (1uF, 10uF, 220uF, 100uF, and 47uF)
  • Variable resistor of 5K ohms.
  • Lithium Cell 18650
  • LEDs
  • Diodes 1N5824
  • Resistors (1K ohm, and 1,2 K ohms)

 

3. Basic Circuit Diagram

 

The following is the basic circuit diagram of the power bank circuit.

 

Power Bank Circuit on PCB2.png

 

4. Working of the main Circuitry

 

The main circuit diagram of the project has two main portions, one being the power bank charging circuitry and the other being DC to DC converter. The charging circuitry is being made with TP4056 and the converter is made with the XL6009. The converter is for boosting the voltage from 3.7V to 4.5V or 6V as required by the cell phone. The voltages are variated through a potentiometer to get the required level. The micro USB pin is used for the charging of the lithium cell (18650) and a female USB connector is utilized for the charging of the phone. Sliding Switch is also used for the altering the charging mode of the 18650 cell of the phone

 

Power Bank Circuit on PCB3.png

 

5. The PCB Design of the Circuitry of Power Bank

 

The PCB can be designed through many software, however EDA is recommended to be used for the design of printed circuit board. The easy EDA is convenient and easy to use, this is why the software is highly recommended.

 

Before implementing the design of printed circuit board of the power bank, it is highly recommended that schematics of the circuit must be run successfully. This is because when you are having error free running simulations of the circuitry, you can make the connections easily in its PCB design and have an error free connections.

 

You are required to place the traces for the circuit and meanwhile you will place the components that you require in the circuit. For example, either you place all the components for the design, and then connect each component or first place the traces and then place vias for the components. All it depends on your own need and ease.

 

The PCB is from WellPCB,a manufacturer of printed circuit boards.I got my PCBs in 4 days with excellent quality. Therefore, if you are not able to make your own PCBs, provide its layout or circuit design to well PCBs, they can make for you.

 

The following is the design of the power bank circuitry.

 

Power Bank Circuit on PCB4.png

 

6. Etching, Drilling, and Soldering

 

When you finalize the design, you have to print it on the glossy paper and cut the PCB board and paste over it. However, you need to keep it under hot iron to paste the design over PCB board. The next step is to etch the circuit using the copper sulphate solution. After that you are required to check connectivity of the circuit. Drill the vias and then using soldering iron put the components on to the circuit.

 

This is how the circuit of power bank look like after drilling and components soldering.

 

Power Bank Circuit on PCB5.png