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  • Author Author: shabaz
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BBB - Rechargeable on-board battery system

shabaz

Note April 2017: There are different revisions of the BeagleBone Black since this post was written in 2013, and without testing them all, it is the user's decision whether to try this solution or not. The revision changes are listed here and a possible option for at least some revision boards is shown in the photo here but I've not investigated this. The newer BeagleBone Blue already has a battery connection, so that is another option.

 

This posting is about implementing a rechargeable battery system for the BeagleBone Black. It is simple, safe and very low cost (less than 6 Euro).

 

image

 

First, some brief information about the power circuitry on the BBB.

 

The BBB has a built-in power management IC (PMIC) based on the TI TPS65217C device. This device contains multiple switch-mode regulators and LDO regulators to provide all voltage levels needed for the entire board. It handles wake-up using a push-button fitted on the BBB. Automatic power-down via the button requires some software to be implemented (to do the equivalent of 'shutdown now' from the command line). When the button is pressed, an interrupt is generated and the microprocessor is supposed to query the PMIC (via I2C) to learn that the button was pressed, and kick off the shutdown sequence. In the event of a failure here, the power can be switched off by holding the button down for 8 seconds.

The IC also contains built-in battery charging capability.

Apart from the USB requirement of 5V, there is no need to run the BBB from 5V; it can happily run from a lower supply. This means that a single 3.7V cell could be used to power the entire board. No need to step-up to 5V or to run dual cells and step-down to 5V, both of which could have been inefficient.

Why is this useful?

It makes it an excellent platform for outdoor/portable use.

For indoor use a battery is useful because it serves as a backup supply in case the main power (from a mains powered supply or from USB) gets disconnected. It could prevent filesystem corruption. If the main supply gets disconnected, the battery immediately takes over. In fact, I permanently leave the battery connected even when I'm running from the mains supply, in case I forget to safely shutdown the board.

What battery can be used?

Any small Lithium Ion (Li-Ion) or Lithium Polymer (Li-Po) single cell can be used, preferably as long as it has a built-in protection circuit. If it doesn't have an in-built circuit, it is highly advisable that one with a built-in thermistor is used. A cell in the range 700mAH to around 2AH is advisable. The one that I used in the photo above is from Olimex part code BATTERY-LIPO1400mAh. It should last around 3.5 hours (EDIT: Now been measured, it lasts 2 hours 50 minutes - see notes below, and comments below) on a full charge (not measured) and should fully charge in around 2 hours. This particular battery is just the right size to fit in between the two rows of headers and is flush so that a cape can still be plugged on top. So, the entire thing can fit inside any enclosure.

You will also need a connector (see next section) and one resistor.

Construction detail

The BBB has four holes that are suitable for connecting up the battery. They are detailed in the BBB system reference manual (SRM):

image

This is what they look like:

image

The Olimex Li-Po has a built-in protection circuit, so I soldered a 10k resistor to TS and GND to simulate the thermistor. (EDIT: You may or may not wish to do this, please study Li-Po and use your own judgement - see comments below) It is desirable to use a connector for the Li-Po.

The LiPo connector was convenient to solder to pins TP6 and TP8, and then  a zero-ohm link between TP5 and TP6 on the underside.

Here is how it was done step-by-step (there are just two steps):

1. Solder the 10k resistor, and a zero-ohm link (both are achieved on the underside of the board) as shown here in the yellow box. These are simple 0603 resistors; I used a 1% tolerance resistor, but 5% should be fine.

image

2. Solder in the connector.

This is straightforward, but complicated slightly by the fact that the connector has 2mm pin spacing, but the board has 0.1" spacing. It means that the pins on the connector need to be splayed or bent into the correct spacing. The connectors are available in vertical mount or right-angle (RA) mount. If you use a vertical mount connector, there may not be enough space to splay the pins. Instead, I used a right-angle connector and bent the pins into a vertical orientation, and then I had space to bend the pins and still have the connector flush with the board as shown here. You can see another view of the connector from the first photo.

image

I'm fairly sure that the desired connector is JST 'PH' series.

 

That's it; plugging in the battery, the board worked instantly. Note that the Li-Po charge method is usually to have a constant current supplied to the battery until it reaches a certain, very precise voltage. After that the charger switches to a constant-voltage mode. For the Li-Po battery that I used, the charger needs to be set to 4.2V, but the BBB by default sets it to 4.1V (It can be set to 4.2V via I2C control but today it doesn't). I'm not sure what the impact of this is (beyond storing less charge), but I believe it is safe. I have been using it daily for three months and the battery is always cool to touch.

Controlling the PMIC

The TPS65217C PMIC is very programmable; it has dozens of configuration settings specifically for charging and it has safety timer capability. The PMIC is configured upon startup via I2C. There are three I2C busses on the BBB, and one is dedicated to on-board peripherals. Control of the PMIC is not normally possibly by the user; it requires driver code or possibly there is access by the device tree infrastructure. Checking the .dts file in /boot did not reveal how to control the battery charger functionality. There are two current Google Summer of Code (GSoC) projects that touch on PMIC:

1. IIO, ADC, PMIC, LCD debug/patchwork (summary page, blog page) - Zubair Lutfullah

2. MINIX I2C drivers (summary page, blog page) - Thomas Cort

Hopefully the guys working on the projects (Zubair and Thomas) can offer some advice on how to set the level to 4.2V. Zubair's project also includes how to use the in-built ADC inside the AM3359 to monitor voltages.

Notes

There really should be some more detail including measurements to show how long the battery lasts and to observe the charging status (via I2C reads). Unfortunately I didn't have time to collect this information. But I've been using it for three months regularly and it functions well.

EDIT: The following simple test was conducted using the Olimex battery referred to above.

1. Power up the BBB using the DC power supply and let it charge the battery while powering the BBB

2. After about 4-5 hours, the DC supply was disconnected, and a script was run on the BBB to log the current date/time to a file, every minute. The script would sleep in-between. The Ethernet connection was left up, and the BBB was left alone until the battery died, and then the log file was examined.

 

#!/bin/bash
while true; do
date >> log.txt
sleep 60
done

 

The result was that the log file showed that the BBB ran for 2 hours 30 minutes before it died. After this, the test was repeated. The second time, it ran for 2 hours 50 minutes. The discrepancy may be because this battery has never been fully charged followed by such a long discharge, and so perhaps it is related to that. No test has been run with the Ethernet disconnected, but the BBB should run for longer in that case of course.

In a third test, the battery again ran for  2 hours 50 minutes (to within 1 minute). Again, this was with the Ethernet interface up.

  • in reply to Former Member

    Hi selsinork,

     

    They do look nice.

    mentioned these recently in a PM, they look interesting, and especially useful if USB is required (otherwise the BBB will happily run off a LiPo without the additional circuitry). Hopefully the range can expand (at least the smaller end - the larger model is pricey). We were wondering why it wasn't designed for higher input voltage, for automotive and industrial use too. That would make it very attractive for the smaller board.

     

    For the scenario that a backup supply is needed momentarily for when main power is removed (for a graceful shutdown),  I've noticed the recent debian images will initiate a shutdown automatically, assuming that a LiPo is directly connected. Power-up occurs when the main supply is reconnected, or via the switch on the BBB (for battery-only power, or if the BBB was shutdown using the switch rather than accidental main power disconnect).

     

    I'm working on a (work-related) experiment that will use the BBB, where I have such a requirement, so I'm planning to use a smaller 850mAh battery (since I only need it to run the BBB for the few minutes while it shuts down - but I think going less than 850mAH may be unwise because I have not made any changes to PMIC configuration for adjusting charge current (if that is possible).

     

    However I'm constrained for space in the enclosure so there will be a sandwich of BBB, battery and then my application-specific cape plugged on top, i.e. the whole thing taking up no additional vertical height beyond the height of the Ethernet socket. I'm hoping it doesn't get too warm in there, otherwise I may need to rethink this : ( I have separated the BBB and battery slightly with some 2mm-thick corrugated card as a temporary air gap experiment. It does seem to keep the battery cool (presumably any heat from the BBB is now being conducted through the PCB or below - not that the BBB gets more than slightly warm anyway). The 850mAH battery also helps that assuming the application-specific cape does not need 5V, then it should be able to optionally run on battery-only power for 1 to 1.5 hours or so.

    image

  • in reply to Former Member

    Hi Markus,

     

    Yes it does help alleviate some PSU issues which is nice. Sometimes if I am working at the desk with the BBB powered up, I can just unplug the 5V supply and move the board elsewhere, maybe to another room, without needing to shutdown the board. It may seem a little thing but it is surprisingly great to be able to do this easily with the BBB.

  • I added a 2000mAh battery with a PCM and it seems to work pretty well. The best advantage is while I power the unit from a 5V source. The wall adapter I have was rated at 1.2A but the initial current was high enough to drive it into over-current, causing it to drop out the voltage and preventing the board from ever booting. Once I hooked up the battery that's not a problem anymore.

     

    Before I ran into this I had built a power bank to use through the 5V plug, but this seems to work a lot better, since I don't need to worry about boosting the voltage to 5V.

  • in reply to Former Member

    A few comments re posts

     

    1) SYS_5V Rail

    The SYS_5V rail will have power if a battery is fitted.  TBH this line SHOULD NOT BE USED TO DIRECTLY POWER ANYTHING.  Instead create a new power rail fed from this and gating it from one of the power rails (I would suggest VDD_3V3AUX as that is also used to gate the VDD_3V3B secondery PSU). 

    Why?

    Because any device relying on the Sys5V rail will almost cirtainly be connected to somthing controlling it from outside the sys_5V power domain - i.e. GPIO lines from the SoC.  you run the risk of back feeding (latchup) the SoC through the IO lines when the SoC is turned off.  Issolation and Power domain control is very important when dealing with battery power.  Even nA's of back feed current can cause a problem.  HINT: pay carfull attention to buses!

     

    2) Power Switch

    The PMIC always expects to have power from a battery (that is what the Ti team envisaged when it was being designed).  On the BBB (and on several products with PMICS I have previously designed) this is not true.  We rely on a feature of the PMIC to start the processor whenever power is applied (cold start).  However from that point onwards the PMIC is expecting to be told to turn off via an I2C command.  further starts are therfore caused by pulling the PB_IN line to ground (or from an RTC interrupt in the case of other PMICS in the Pheonex family).  If you wish for the unit to boot when power is applied (eiether from VDD_5V or USB_DC) then you should really create a pulse on the PB_IN input (this can be as simple as an R/C feed into the base of an NPN transistor connected between PB_IN and Ground.  Although it may be better to derive the pulse from a monostable perhaps powered from the VRTC power domain.

     

    3) Coulomb counting

    This PMIC doesn't contain a coulomb counter (later devices in the Pheonix series do).  They are however very usefull for estimating battery life left.  Li based secondery cells have a very steep battery discharge curve - meaning that they provide an almost constant output voltage as they discharge before falling sharply when they are flat.  Noticing this drop off before it is too late is almost impossible (much much easier in Ni based cells), So instead we use a coulomb counter and a couple of 'fudge factors'.

    Measure the voltage and current being put into / out of the battery (V at terminal Bat1 and also accross a shunt resistror between this tertminal and the battery itself).  Knowing both V and I Bat allows you to calculate the instantainious power to or from the battery.  repeat this sample often enough and you are able to measure charge in and out of the battery (I use a small AVR micro to do this - other microcontrollers or dedicated coulomb counter ICs are available). 

    Now this is not an exact sciance - we only know what the power sue/consumption was at the time of the sample so we assume it to be constant between each sample but it may have peeked or toughed.  To compensate I assume a dischage fudge factor of 5% i.e. I assume that we have discharged 5% more than measured (but when charging I don't apply this fudge) that way I should err on the side of having slightly more capacity left in the battery than anticipated.

    Likewise is derate batteries by their age - Li based secondery cells typically last between 300 & 400 charge cycles before their capacity falls to arround 50%.  Simply counting the number of charge cycles and derating the 'fully charged' capacity of your battery each time tends to work well.  Both fudge factors appear to work well enough but can be improved by huristics if you want to take it further.

     

     

    /Andy