Introduction: How to Make a HIGH Current Driver for a Stepper Motor

here we will see how to make a stepper motor driver using Toshiba's TB6560AHQ controller.

This is a full featured controller which only needs 2 variables as input and it does all the work.
Since I needed two of these I've made both of them using the same method.

edit 04.2020: Unfortunately the source files have been lost along my home desktop computer so... all you see here is also all I got now.

Step 1: Making the PCB

Since it's a DIY project here is the PCB as it was being made:
- first get the circuit on the copper plated board (NOTE: IT HAS TO BE DOUBLE FACED)

the way i did it:
1. i printed the circuit on a glossy paper using a laser printer
2. adjust the 2 circuits so they match, facing each other
3. place the copper plated board between them
4. place the sandwich between a folded regular piece of paper
5. using a hot iron press on the folded paper
6. flip it and repeat
7. afterwards take "the sandwich" and get it wet using cool water
8. press on the paper until the circuit becomes visible and there aren't any air bubbles
9. remove the paper.

you should get something like this:

NOTE: the PDFs are scaled 1:1 and only need to be printed DO NOT MIRROR THEM WHEN PRINTING!!!

Step 2: Finishing the PCB

Get the plate with the printed circuit and place it into a corrosive solvent and agitate it a bit to speed up the process.
You should get something like this:
After that you can clean it with any kind of detergent:

Step 3: Completing the Circuit

After you made sure that all is well and drilled holes in all the right places it's time to complete the circuit. You'll see that one line gets interrupted then is continued on the other side and back on the original side.
I've done this by using thin copper wire. as many as needed (small lines - 2 wires, thick lines - 4 wires) since the driver can support up to 3.5A

Step 4: Soldering Time

it's now time to solder the components and apart from the 2 100uF capaitors, all the other parts are SMD.
you have here a schematic of the circuit and the part list


you will see that 4 resistors do not have the value written. that is because the vary according to the motor you use!

Step 5: Checking the Circuit

after you have completed the soldering make sure that nothing is soldered accidentally to the GND.
cover the finished driver with a protective layer to avoid corrosion.

this driver can perform at 20%(00), 50%(01), 75%(10) or 100%(11) depending on how you have the right switches positioned as shown in brackets.

Have fun guys!