Battery-Powered Fan Controller Design

flux

I found low-cost battery options: TP4056 charger, JST-PH LiPo connector, a buck-boost 3.3 V rail for the ESP32, and an optional 5 V boost stage for the fan if the fan must run from the battery.

flux

Implemented the first-pass schematic for a low-cost rechargeable LiPo thermocouple fan controller with ESP32-C6 BLE/Wi‑Fi, MAX31855 K-type thermocouple input, TP4056 USB-C charging, 3.3 V buck-boost regulation, and PWM fan drive with optional 5 V boost. I also added project docs: spec, bring-up plan, firmware notes, and regulatory/safety notes. Initial ERC-style checks came back with no open warnings/errors in the checked categories.
Open items:
  • Confirm fan voltage/current and whether it must run fully from the internal battery.
  • Confirm desired runtime and battery capacity.
  • Decide whether phone-only UI is enough or if you want a small display.
  • Confirm thermocouple connector style: screw terminal vs proper miniature thermocouple jack.
Suggested next steps:
  1. Pick the actual fan/blower and battery capacity.
  2. Add battery voltage measurement so the phone UI can show charge level.
  3. Move to PCB layout with antenna clearance and charger/boost thermal placement.
  4. Add a basic ESP32 firmware skeleton for BLE/Wi‑Fi provisioning, thermocouple readout, and fan PID control.
Set fan and battery
Use 5V blower
Add battery sensing
Start PCB layout
Check BOM cost
Phone-only UI

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Regulatory and Safety Notes
Wireless
The design uses an ESP32-C6 module with integrated radio. Keep the module antenna area clear in PCB layout and follow Espressif module integration guidance to preserve modular certification assumptions.
Battery Safety
Use a protected single-cell LiPo pack unless a protection IC is added to the PCB. Verify charge current against the selected battery capacity and thermal behavior of the TP4056.
Thermal / Grill Environment
Keep the electronics enclosure away from direct grill heat, smoke condensation, and rain. Use a proper thermocouple extension/connector rated for the expected temperature.
Fan Output
The first revision assumes a small fan up to about 1 A. Final MOSFET/boost thermal validation depends on the selected fan voltage/current.

  • Wireless

  • Battery Safety

  • Thermal / Grill Environment

  • Fan Output

Thermocouple Fan Controller

Thermocouple Fan Controller thumbnail
Low-cost rechargeable LiPo BBQ/smoker fan controller using an ESP32-C6, K-type thermocouple input, BLE/Wi‑Fi phone connectivity, and PWM fan output.

Properties

Battery

Low-cost rechargeable single-cell LiPo architecture with USB-C charging

Buttons

WiFi

5

V

IoT

Bluetooth

Pricing & Availability

Distributor

Qty 1

Arrow

$6.48–$7.54

Digi-Key

$8.99–$9.05

HQonline

$2.67–$3.33

LCSC

$11.84–$11.96

Mouser

$19.26–$19.34

TME

$5.44

Verical

$5.64–$6.66

Controls