DIY USB-C PD Tools

USB-C PD Decoded: A DIY Meter And Logger For Power Insights

As USB-C PD becomes more and more common, it’s useful to have a tool that lets you understand exactly what it’s doing—no longer is it limited to just 5 V. This DIY USB-C PD tool, sent in by [ludwin], unlocks the ability to monitor voltage and current, either on a small screen built into the device or using Wi-Fi.

This design comes in two flavors: with and without screen. The OLED version is based on an STM32, and the small screen shows you the voltage, current, and wattage flowing through the device. The Wi-Fi PD logger version uses an ESP-01s to host a small website that shows you those same values, but with the additional feature of being able to log that data over time and export a CSV file with all the collected data, which can be useful when characterizing the power draw of your project over time.

Both versions use the classic INA219 in conjunction with a 50 mΩ shunt resistor, allowing for readings in the 1 mA range. The enclosure is 3D-printed, and the files for it, as well as all the electronics and firmware, are available over on the GitHub page. Thanks [ludwin] for sending in this awesome little tool that can help show the performance of your USB-C PD project. Be sure to check out some of the other USB-C PD projects we’ve featured.

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Compact Driver Powers Steppers With USB-C PD

NEMA-17 steppers are (almost) a dime a dozen. They’re everywhere, they’re well-known to hackers and makers, and yet they’re still a bit hard to integrate into projects. That’s because the motor alone isn’t much use, and by the time you find or build a driver and integrate it with a microcontroller, you’ve probably expended more effort than you will on the rest of the project. This USB-C PD stepper driver aims to change that.

What caught our eye about [Josh Rogan]’s PD Stepper is his effort to make this a product rather than just a project. The driver is based on a TMC2209 for silent operation and a lot of torque thanks to the power delivery capabilities of USB-C PD. The PCB is very nicely designed and has an AS5600 rotary magnetic encoder for closed-loop operation. There’s also an ESP32-S3 on-board, so WiFi and Bluetooth operation are possible — perfect for integration into Home Assistant via ESPHome.

[Josh]’s mechanical design is top-notch, too, with a machined aluminum spacer that fits on the back of a NEMA-17 motor perfectly and acts as a heat spreader. A machined polycarbonate cover protects the PCB and makes a very neat presentation. [Josh] has kits available, or you can roll your own with the provided build files.

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The splitter with a 3D-printed case and three yellow cables coming out of it, powering two phones and one powerbank at the same time

Split A USB-C PD Port Into Three Port-ions

There’s no shortage of USB-C chargers in all sorts of configurations, but sometimes, you simply need a few more charging ports on the go, and you got a single one. Well then, check out [bluepylons]’s USB-C splitter, which takes a single USB-C 5V/3A port and splits it into three 5V/1A plugs, wonderful for charging a good few devices on the go!

This adapter does things right – it actually checks that 3A is provided, with just a comparator, and uses that to switch power to the three outputs, correctly signalling to the consumer devices that they may consume about 1A from the plugs. This hack’s documentation is super considerate – you get detailed instructions on how to reproduce it, every nuance you might want to keep in mind, and even different case options depending on whether you want to pot the case or instead use a thermal pad for a specific component which might have to dissipate some heat during operation!

This hack has been documented with notable care for whoever might want to walk the journey of building one for themselves, so if you ever need a splitter, this one is a wonderful weekend project you are sure to complete. Wonder what kind of project would be a polar opposite, but in all the best ways? Why, this 2kW USB-PD PSU, most certainly.

Design Review: USB-C PD Input For Yaesu FRG7700

Today is another board from a friend, [treble], who wants to convert a Yaesu FRG7700 radio to USB-C PD power. It’s yet another review that I’ve done privately, and then realized I’ve made more than enough changes to it, to the point that others could learn from this review quite a bit. With our hacker’s consent, I’m now sharing these things with you all, so that we can improve our boards further and further.

This board’s idea is thought-out and executed well – it replaces a bespoke barrel jack assembly, and is mechanically designed to fit the screw holes and the free space inside the chassis. For USB-PD, it uses a CH32V003 coupled with FUSB302 – I definitely did help pick the latter! For mechanical reasons, this board is split into two parts – one has the USB-C port, whereas the other has the MCU and the PD PHY.

In short, this board is a PD trigger. Unlike the usual PD triggers, however, this one is fully configurable, since it has a 32-bit MCU with good software support, plus, the PD PHY is also well known and easily controllable. So, if you want special behavior like charger-power-dependent profile selection for powering a static resistance load, you can implement it easily – or, say, you can do PPS for variable voltage or even lithium ion battery charging! With a bit of extra code, you could even do EPR (28 V = 140 W power) with this board, instantly making it into a pretty advanced PD trigger, beyond the ones available on the market.

Also, the board has some PCB art, and a very handy filter to get some of the USB-C charger noise out. Let’s take a look at all of these!

Current Flow Improvements

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USB-C PD: New Technology Done Right

There is a tendency as we get older, to retreat into an instinctive suspicion of anything new or associated with young people. All of us will know older people who have fallen down this rabbit hole, and certainly anything to do with technological advancement is often high on their list of ills which beset society. There’s a Douglas Adams passage which sums it up nicely:

“I’ve come up with a set of rules that describe our reactions to technologies:
1. Anything that is in the world when you’re born is normal and ordinary and is just a natural part of the way the world works.
2. Anything that’s invented between when you’re fifteen and thirty-five is new and exciting and revolutionary and you can probably get a career in it.
3. Anything invented after you’re thirty-five is against the natural order of things.”

Here at Hackaday we’re just like anybody else, in that we all get older. Our lives are devoted to an insatiable appetite for new technology, but are we susceptible to the same trap, and could we see something as against the antural order of things simply because we don’t like it? It’s something that has been on my mind in some way since I wrote a piece back in 2020 railing at the ridiculous overuse of new technologies to limit the lifespan and repairability of new cars and then a manifesto for how the industry might fix it, am I railing against it simply because I can’t fix it with a screwdriver in the way I could my 1960 Triumph Herald? I don’t think so, and to demonstrate why I’d like to talk about another piece of complex new technology that has got everything right.

In 2017 I lamented the lack of a universal low voltage DC power socket that was useful, but reading the piece here in 2024 it’s very obvious that in the years since my quest has been solved. USB Power Delivery was a standard back then, but hadn’t made the jump to the ubiquity the USB-C-based power plug and socket enjoys today. Most laptops still had proprietary barrel jack connectors, and there were still plenty of phones with micro-USB sockets. In the years since it’s become the go-to power standard, and there are a huge number of modules and devices to supply and receive it at pretty high power.

At first sight though, it might seem as though USB-PD is simply putting a piece of unnecessary technology in the way of what should be a simple DC connector. Each and every USB-PD connection requires some kind of chip to manage it, to negotiate the connection, and to transform voltage. Isn’t that the same as the cars, using extra technology merely for the sake of complexity? On the face of it you might think so, but the beauty lies in it being a universally accepted standard. If car manufacturers needed the same functionalty you’d have modules doing similar things in a Toyota, a Ford, or a Renault, but they would all be proprietary and they’d be eye-wateringly expensive to replace. Meanwhile USB-PD modules have to work with each other, so they have become a universal component available for not a huge cost. I have several bags of assorted modules in a box of parts here, and no doubt you do too. The significant complexity of the USB-PD endpoint doesn’t matter any more, because should it break then replacing it is an easy and cheap process.

This is not to say that USB-PD is without its problems though, the plethora of different cable standards is its Achilies’ heel. But if you’re every accused of a knee-jerk reaction to a bad piece of new technology simply because it’s new, point them to it as perhaps the perfect example of the responsible use of new technology.

Freshening Up Google’s USB-C PD Sniffer

USB-C Power Delivery has definitely made the big mess of wires a bit smaller but not all cables are created equal — some of them can handle upwards of 100 W while the cheapest can handle only 10. To accommodate this, USB-C cables need to actively tell both ends what their capabilities are, which turns an otherwise passive device into a hidden chip in a passive looking cable.

[Greg Davill] has decided to unravel the mystery of why your laptop isn’t charging by creating a USB-PD sniffer. Based on Google’s Twinkie sniffer, the FreshTwinkie makes the design more accessible by reducing the number of layers in the PCB and replacing the BGA variant of the STM32 for a more DIY-friendly QFN version. Interestingly, this isn’t the first time we’ve seen somebody try and simplify the Twinkie; back in 2021, the Twonkie from from [dojoe] hit a number of similar notes.

USB-C Power Delivery is just one of many protocols spoken over the CC pins, and the FreshTwinkie might be able to detect when some of those are enabled and why or why not. With future development, it could potentially provide useful information as to why a Thunderbolt 4 or tunneled PCIe device isn’t working correctly.

All About USB-C: Replying Low-Level PD

Last time, we configured the FUSB302 to receive USB PD messages, and successfully received a “capability advertisement” message from a USB-C PSU. Now we crack the PD specification open, parse the message, and then craft a reply that makes the PSU give us the highest voltage available.

How did the buffer contents look, again?

>>> b
b'\xe0\xa1a,\x91\x01\x08,\xd1\x02\x00\x13\xc1\x03\x00\xdc\xb0\x04\x00\xa5@\x06\x00<!\xdc\xc0H\xc6\xe7\xc6\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00\x00'

The zeroes at the end might look non-significant, and they indeed are not with 99.99% certainty – that said, don’t just discard the entire tail end; one of the bytes in the beginning encodes the length of the message. We’ll read those bytes first, and then read only exactly as much as we need, making sure we aren’t reading two messages and interpreting it as one, and that we’re not discarding zeroes that are part of the message.

Today, we will write code that parses messages right after reading them from the FIFO buffer – however, keep this message handy for reference, still; and if you don’t have the hardware, you can use it to try your hand at decoding nevertheless. If you wanna jump in, you can find today’s full code here!

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