Project Overview

This wireless stepper motor controller integrates an ESP32-S3 microcontroller with a TMC2240 stepper driver and AS5600 magnetic encoder, creating a Wi-Fi-enabled motor control system that can be operated through any web browser.

Key Technical Components

Core Hardware:

• ESP32-S3-WROOM-1: Provides Wi-Fi connectivity and system control
• TMC2240 Stepper Driver: Delivers ultra-quiet, precise motor control with up to 1/256 microstepping
• AS5600 Magnetic Encoder: Enables closed-loop position feedback for accurate angle tracking
• FUSB302BMPX USB-C PD Controller: Automatically negotiates power from 5V to 20V
• ADP4140002 LDO Regulator: Provides stable 3.3V for system components

Smart Features:

Web-based control requiring no special software, Wireless Stepper Motor Controller with ESP32 and TMC2240

Real-time monitoring of motor temperature, current draw, and exact position. Wireless Stepper Motor Controller with ESP32 and TMC2240

RGB LED indicators showing power status and motor activity through colour-coded feedback. Wireless Stepper Motor Controller with ESP32 and TMC2240

Automatic power negotiation from USB-C PD sources, Wireless Stepper Motor Controller with ESP32 and TMC2240

Physical Design

The PCB measures exactly 42.3mm x 42.3mm, matching NEMA 17 stepper motor dimensions for direct mounting behind the motor Wireless Stepper Motor Controller with ESP32 and TMC2240. The system includes a laser-cut enclosure with strategic ventilation for the driver IC and proper magnet placement for the encoder.

Software Architecture

The Arduino-based firmware integrates multiple libraries and provides:

HTTP API endpoints for all motor functions (enable/disable, speed control, angle positioning)

Real-time sensor monitoring with cached values to optimise performance

Power delivery management with automatic voltage negotiation

Non-blocking operation ensuring web responsiveness during motor movements

Control Capabilities

Precision Movement: Variable microstepping from full-step to 1/256 microstepping

Angle Positioning: Direct angle commands with automatic tolerance calculation

Speed Control: Dynamic speed adjustment with proximity-based deceleration

Current Control: Adjustable motor current from the web interface

Emergency Stop: Immediate motor shutdown capability

Power Management

The system automatically negotiates optimal power levels from USB-C Power Delivery sources, supporting 5V, 9V, 12V, 15V, and 20V profiles. Wireless Stepper Motor Controller with ESP32 and TMC2240, with colour-coded LED feedback indicating the current power level.

This project represents an excellent example of modern IoT motor control, combining precision hardware with intuitive web-based control for applications in robotics, automation, and prototyping.

This is a comprehensive wireless stepper motor controller project that combines several advanced technologies into a compact, web-controlled system. You can have a clear working principle by visiting the source from this link: Wireless Stepper Motor Controller with ESP32