This video introduces a custom-designed USB-C Power Delivery (PD) trigger board created to replace proprietary barrel jack power inputs on various electronic devices. The primary goal is to declutter and standardize power connections by converting equipment to use the modern USB-C standard, eliminating the risk of using incorrect power adapters. The creator showcases a compact PCB that fits within the form factor of a standard barrel jack, allowing for a clean, direct replacement. Key design features include the use of the WCH CH224K chip for voltage negotiation and a crucial improvement over reference designs: a low-dropout (LDO) regulator to power the chip, which prevents overheating when using higher voltages.
The second half of the video serves as a comprehensive tutorial on how to order these boards fully assembled through the JLCPCB SMT service. It provides a step-by-step guide, from uploading Gerber, BOM, and CPL files to navigating the component verification and placement confirmation stages, offering practical tips to avoid common pitfalls in the ordering process. The design files are made available for viewers to use.
Upgrading Your Gear: A Guide to Creating and Ordering Custom USB-C Power Converters
00:00:02 The Problem of Power Adapter Clutter: The video highlights the common issue of managing numerous different barrel jack power adapters, which creates clutter and the risk of connecting the wrong voltage or polarity to a device.
00:00:41 A Custom Solution for Clean Conversions: Existing USB-C trigger modules are often not suitable for cleanly retrofitting equipment. The creator designed a compact PCB that perfectly fits the footprint of a standard barrel jack, allowing for a seamless replacement.
00:01:49 Versatile and Robust Design: The custom board can be mounted using simple tinned copper wire or pin headers. By flipping the board, it can support both center-positive and center-negative polarity configurations, common in different types of electronics.
00:03:18 Simple Voltage Selection: The board is configured to output 9V by default. Users can create solder bridges on two pads to select other standard USB-C PD voltages: 12V, 15V, or 20V.
00:04:25 Technical Chip Choice: The design is based on the WCH CH224K, a widely available and popular USB-PD controller chip, chosen for its availability and suitable package size.
00:06:07 Key Design Improvement to Prevent Overheating: Unlike typical reference schematics that use a simple resistor to power the controller chip (which can get extremely hot at 20V), this design incorporates a Low-Dropout (LDO) regulator. This makes the board more efficient and prevents dangerous heat dissipation across the full 9V-20V range.
00:07:07 Open-Source and Available to Order: The creator is not selling the boards but has made all the necessary files (Gerber, Bill of Materials, Component Placement) available for anyone to order them directly from an assembly house like JLCPCB.
00:07:42 Detailed JLCPCB Ordering Tutorial: The video provides a complete walkthrough of the JLCPCB assembly order process. This includes uploading the design files, specifying PCB parameters like 0.8mm thickness, and adding notes for special features like plated slots.
00:09:29 Preparing Files and Avoiding Errors: The tutorial offers crucial tips for a successful order, such as the correct formatting for component designators in the BOM file and ensuring no cells are left blank to prevent parsing errors.
00:12:18 Verifying Components and Placement: A critical step is carefully reviewing the component list matched by JLCPCB and visually confirming the placement and rotation of every part on the board using the web preview tool.
00:15:45 Finalizing the Order and Shipping: The guide concludes with the final steps of placing the order and includes a warning that shipping weights can sometimes be overestimated, advising users to contact support for a re-weigh if the cost seems excessive.
00:16:23 Project Files and Community Contribution: The video ends by directing viewers to a resource page with all project files. The creator notes the design was made in PCAD but welcomes a community-submitted KiCad version.