Connecting Everything with USB-C
In a bid to address the pervasive problem of Wall Wart Hell, a new project demonstrates the potential of USB-C Power Delivery (PD) technology. The project, presented by Mikeselectricstuff, aims to replace traditional barrel jack sockets on PCBs with modern USB-C PD power supplies.
This innovative approach offers several advantages. By converting the legacy power input to accept USB-C PD, devices gain more flexibility, modernity, and standardization in their power sources.
To achieve this, a dedicated USB-C PD controller chip designed for barrel jack replacement is used. Infineon's EZ-PD™ Barrel Connector Replacement (BCR) family, such as the CYPD3177-24LQXQT or the BCR-Lite variant, is an ideal choice. These chips offer a USB Type-C transceiver and PD policy manager, integrated power switches, gate drivers, and protections against overvoltage, undervoltage, overcurrent, shorts, and ESD. They also provide compatibility with legacy barrel connector voltages up to 100W (5V to 20V, up to 5A) and easy configuration via simple interfaces.
The hardware design process involves removing the existing barrel jack socket from the PCB, designing or ordering a replacement board or module that hosts the USB-C connector and the PD controller chip, ensuring correct connections between the power input lines and the PD controller output, adding passive components as specified in the controller chip datasheet, and addressing mechanical mounting and strain relief for the USB-C connector.
One of the key benefits of these controller chips is that they require no firmware development, as the USB PD stack and policy management are integrated in hardware. This simplifies the upgrade process considerably.
Mikeselectricstuff has showcased a project that replaces barrel jack wall warts with USB-C PD power supplies using such chips. The project includes open design files and a comprehensive video explaining the implementation process in detail. This project aims to eliminate legacy wall wart clutter and adopt USB-C PD cleanly.
A summary table of key components features is provided below:
| Component / Solution | Max Power | Voltages Supported | Firmware Required | Protections Included | Notes | |--------------------------------|-----------|--------------------|-------------------|-------------------------------------|-----------------------------------| | Infineon CYPD3177-24LQXQT BCR | 100 W | 5V, 9V, 12V, 15V, 20V | No | OVP, overcurrent, VBus short, ESD | 24-pin QFN, highly integrated | | Infineon EZ-PD™ BCR-Lite | Up to 15 W or more | 5V, 9V, 12V etc. | No | OVP, undervoltage, overcurrent, ESD| Plug-and-play, smaller footprint |
By replacing barrel jacks with USB-C PD using these controllers, devices can benefit from a modern, efficient, and safe power solution, eliminating the need for dedicated wall warts and supporting a broad voltage range negotiated dynamically.
For more detailed design, including ordering boards and exact wiring, it is recommended to refer to the project by Mikeselectricstuff on Hackaday. This project serves as a demonstration of the potential of USB-C PD technology to resolve issues and offers a practical solution to the problem of Wall Wart Hell.
This innovative approach using USB-C PD technology and Infineon's EZ-PD™ BCR controller chips allows for the modernization of smart-home devices and gadgets by replacing traditional barrel jack sockets on PCBs with USB-C PD power supplies. By adopting USB-C PD, these devices can benefit from a more flexible, standardized, and efficient power source, as well as protection against various power anomalies.
Moreover, the use of such controller chips simplifies the upgrade process, as they require no firmware development, enabling seamless replacement of legacy smart-home devices and reduction of wall wart clutter. The project demonstrates the potential of USB-C PD technology in addressing the problem of Wall Wart Hell, offering a practical solution for various gadgets and smart-home devices.
