Google-Inspired USB-PD Sniffer For The DIY Crowd

February 20, 2021 by Tom Nardi 11 Comments

If you want to hack around with the communication protocol that USB Power Delivery devices use to negotiate their power requirements with the upstream source, a tool like Google’s Twinkie really helps. With it you can sniff data off the line, analyze it, and even inject your own packets. Luckily for us, the search giant made the device open source so we can all have one of our own.

Unfortunately, as [dojoe] found out, the Twinkie isn’t particularly well suited for small-scale hobbyist manufacturing. So he came up with a revised design he calls Twonkie that replaces the six layer PCB with a much more reasonable four layer version that can be manufactured cheaply by OSHPark, and swaps out the BGA components with QFP alternatives you can hand solder.

That said, it’s still likely to be a challenging build for the home gamer. There’s quite a few 0402 passives on there, and while those are doable with an iron, it can certainly be tricky. To take some pressure off, [dojoe] says he tried to optimize the board layout as much as possible for hand assembly. He was even able to avoid needing hot air by straddling the PCB with USB-C mounts intended for vertical applications.

Given the current chip shortage, [dojoe] says the biggest problem might actually getting your hands on the STM32F072CB microcontroller at the Twonkie’s core. To that end, the board supports TQFP44 and QFN44 footprints, and you can even use a STM32F072C8 at the cost of some functionality. With a bit of luck, hopefully you can find a chip that will work in the parts bin.

GBA Gets Homebrew USB Charging Upgrade

February 6, 2021 by Tom Nardi 18 Comments

Sure there are pre-made kits to add a rechargeable battery and USB-C compatibility to Nintendo’s venerable Game Boy Advance, but [HorstBaerbel] thought he could throw together something similar for a fraction of the price. Plus, he wouldn’t have to wait on shipping. The end result might not be quite as polished, but it’s certainly impressive for what’s essentially a junk bin build.

The star of the show is the popular TP4056 lithium-ion charger module. [HorstBaerbel] went with the more common micro USB version, but these boards are also available with USB-C should you want to embrace the future. The module fits nicely inside the original battery compartment while while still leaving room for a 1,000 mAh pouch cell. The 4.2 V output of the fully charged battery is a bit too high for the Game Boy’s liking, so he used the forward voltage drop of a diode to bring it down to a more acceptable 3.5 V.

Naturally this does waste a good deal of energy, especially compared to the DC-DC converters used in commercial offerings like the CleanJuice, but it still delivers a respectable seven hours of runtime. The only issue with this modification seems to be that you’ve got just five minutes to save your progress and shut down when the GBA’s low-battery light goes on; but what’s life without a little excitement?

While not nearly extreme as some of the other GBA modifications we’ve seen over the years, this project is yet another example of the seemingly unlimited hacking potential of Nintendo’s iconic Game Boy line.

A USB-PD Laptop Conversion In Extreme Detail.

February 3, 2021 by Jenny List 31 Comments

With USB-PD slowly making wall wart power supplies obsolete and becoming the do-it-all standard for DC power, it’s a popular conversion to slap an off-the-shelf USB-PD module in place of the barrel jack in a laptop. Not when it comes to [jakobnator] though, who fitted his Dell with an upgrade lovingly and expertly crafted for both electrical and mechanical perfection.

The video that you can find below the break is a long and detailed one, but in that detail lies touches that set the conversion apart from the norm. We’re treated to a full-run-down of USB-PD module design and chip programming, and then the mechanics of the 1-wire chip through which the Dell ties itself in with only Dell power supplies. Programming this chip in particular is something of a challenge.

It’s the mechanical design that sets this one apart. He started with an odd-shaped space that had contained the barrel jack socket and a ferrite choke, and designed a PCB to fit it exactly. 3D-printing a model to check for fit is attention to detail at the stratospheric level. The result is a fit that looks almost as though it was part of the original manufacture, and which should keep the laptop useful for years to come.

This may be the most elegant USB-C laptop conversion we’ve seen, but it’s not the only one.

Continue reading “A USB-PD Laptop Conversion In Extreme Detail.” →

USB-C Charging On Your ThinkPad, One Step At A Time

January 30, 2021 by Tom Nardi 10 Comments

Hackers love their ThinkPads. They’re easy to work on, well documented, and offer plenty of potential for upgrades. For the more daring, there’s also a wide array of community-developed modifications available. For example, [Berry Berry Sneaky] has recently put together a step-by-step guide on swapping the common ThinkPad rectangular charging port (also used on ThinkBooks and other Lenovo machines) for USB-C Power Delivery.

Now to be clear, this is not a new concept. But between freely sharing the STL for the 3D printed adapter, providing a full parts list, and providing clear instructions on how to put it all together, [Berry Berry Sneaky] has done a fantastic job of making this particular modification as approachable as possible. For the cost of a common PDC004 Power Delivery “trigger” module and a bit of PETG filament, you can add yet another device to the list of things that work with your shiny new USB-C charger.

While not strictly necessary, [Berry Berry Sneaky] recommends getting yourself a replacement DC input cable for your particular machine before you crack open the case. That will let you assemble everything ahead of time, making the installation a lot quicker. It will also let you keep the original rectangular power jack intact so you can swap it back in if something goes wrong or you decide this whole unified charging thing isn’t quite what you hoped for.

Not a member of the ThinkPad Army? No worries. We’ve seen a lot of interest in using these configurable USB-C trigger modules to upgrade all manner of devices to the new Power Delivery standard or sometimes put together custom battery chargers for their older mobile gadgets.

Retrofitting USB-C To An IPod Nano

January 18, 2021 by Danie Conradie 29 Comments

Some hacks serve a critical need, while others are just for the challenge or fun of it. We suspect the latter was the real reason [David Buchanan] converted a first generation iPod Nano from its original 30 pin connector to USB-C.

[David] bought the iPod with a dead battery, so when he opened the iPod to get the old battery out, he noticed there was enough space to fit a USB-C connector. The original Apple 30 pin connector runs USB 2.0 through four of the pins, so [David] used the original USB cable and identified the appropriate pins and traces with a continuity tester. The connector was destructively removed with side cutters, ripping off all but one of the pads in the process. A hot air station might have made things easier, but we assume he did not have one on hand. The USB-C connector was scavenged from a cheap USC-C to USB Micro adaptor and mounted by soldering the housing directly to the PCB’s ground plane. The three remaining terminals were soldered to the traces with enamel wire.

With the new battery installed, [David] confirmed that both charging and data transfer worked. The IC that handles the button and scroll pad interfered slightly with the new connector, so he filed away some of the IC’s excess. Any open pads close to the new connector was covered with Kapton tape to avoid shorts. The large hole in the enclosure for the 30 pin connection was partly filled in with five-minute epoxy. The final assembled product looks almost factory produced and works as it’s supposed to, so we call this a win.

Retrofitting USB-C connectors in various electronic devices has become a popular hack over the past two years. We’ve seen it done on everything from Thinkpads to soldering irons. Continue reading “Retrofitting USB-C To An IPod Nano” →

USB-C Programmable Power Supply For Any Project

January 16, 2021 by Danie Conradie 57 Comments

USB-C Power Delivery 3.0 (PD3.0) introduces a new Programmable Power Supply (PPS) mode, which allows a device to negotiate any supply of 3.3-21 V in 20 mV steps, and up to 5 A of current in 50 mA steps. To make use of this new standard, [Ryan Ma] create the PD Micro, an Arduino-compatible development board, and a self-contained software library to allow easy integration of PD3.0 and the older PD2.0 into projects.

The dev board is built around an ATMega32U4 microcontroller and FUSB302 USB-C PHY. The four-layer PCB is densely packed on both sides to fit in the Arduino Pro Micro Form factor. The board can deliver up to 100W (20 V at 5 A) from an appropriate power source and shows visual feedback on the PD status through a set of LEDs.

The primary goal of the project is actually in the software. [Ryan] found that existing software libraries for PD take up a lot of memory, and are difficult to integrate into small projects. Working from the PD specifications and PD PHY chip data sheet, he created a lighter weight and self-contained software library which consumes less than 8 K of flash and 1 K of RAM. This is less than half the Flash and RAM available on the ATmega32U4.

[Ryan] is running a Crowd Supply campaign (video after the break) to get some of these powerful boards out in the wild, and has released all the source code and schematics on GitHub. The PCB design files will be released during the last week of the campaign, around 25 January 2021.

USB-C and power delivery are not simple standards, but the ability to add a high-speed data interface and a programmable power supply into almost any project has real potential.

Continue reading “USB-C Programmable Power Supply For Any Project” →

What’s In A USB-C Connector?

October 27, 2020 by Jenny List 30 Comments

Anyone who’s ever put together a bill-of-materials for an electronic device will be familiar with the process of scouring supplier catalogs and data sheets for the best choice of components. The trick is to score the best combination of price and performance for the final product, and for those unused to the process, there are always seemingly identical products with an astonishingly wide variety of prices. It’s a topic [Timon] explores in a Twitter thread, examining a 20-cent in quantity of 100 USB-C socket alongside one that costs only 5 cents, and his teardown provides a fascinating insight into their manufacture.

The parts look so nearly identical that while it’s possible to differentiate between them visually, it’s near impossible to work out which was the cheaper. Some tiny features such as a crack in a metal fold or a bit less plating on the contacts emerge, but even then it’s no guide to the quality as they don’t appear on the same part. It’s only when the metal shell is removed to expose the underlying plastic moulding that more clues emerge, as one moulding is more complex than the other. The more complex moulding provides a better and more reliable fit at the expense of a much more costly moulding process, so at last we can not only identify the more expensive part but also see where the extra cash has gone. It’s a subtle thing, but one that could make a huge difference to the performance of the final assembly and which makes for a fascinating expose for electronic design engineers.

If connectors are your thing, there’s a wealth of fascinating information in their history.