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PCB Blogs Compact USB-to-Banana Adapter -- my take on dougw's design
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  • Author Author: baldengineer
  • Date Created: 28 Feb 2023 8:38 PM Date Created
  • Views 24970 views
  • Likes 17 likes
  • Comments 22 comments
  • bench power supply
  • usb
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Compact USB-to-Banana Adapter -- my take on dougw's design

baldengineer
baldengineer
28 Feb 2023
Compact USB-to-Banana Adapter -- my take on dougw's design

Previously, dougw shared a bench power supply video where he used an adapter he made. It had 4mm banana plugs and a USB port on it. The idea was that he could connect USB devices to a bench power supply.

I loved the idea and he did a great job with it.

But I didn't like how large it seemed. Also, I wanted something that could be inserted in either orientation without blocking the controls of my supplies. After looking around for "PCB mount banana plugs," I found... well, none. There are jacks, sure. But no plugs. You're left with components designed to be attached to a cable. Then I found Ponoma makes panel mount plugs!

image

So that got me thinking. If I used that type of hardware, then how would you get the USB port to be in a usable direction? (Instead of pointing up or down.) THEN, I thought: hey, I can practice making PCBs with mouse bites.

image

In my design, you break off part of the PCB (left side) and then solder (to right side) at 90 degrees using the edge tabs. A Ponoma 4mm Plug  with M3 mounting hardware connects to the plated holes. And a short GCT USB-A  connector solders to the board.

The result is a very compact adapter.

image

However. Do not build this one.

There are several issues with my first design.

  1. After breaking off the plug tab, I soldered it backward. So it results in the USB port's +5 and GND being backward. (Some might consider that a bad thing.)
  2. The plug-tabs are not long enough. They only solder to the top side of the USB board, meaning the solder joints act as a lever point. I should have made the plug-tabs longer so that both the top and bottom could be soldered.
  3. Some minor issues with the mouse bits I still need to resolve.

All that said, I am happy with the break-off design. It worked as I expected. Although, I still have some improvements to make there.

For the second revision, here's my plan:

  1. Add some indicators on the silk screen to clarify which side is the "top" for the USB connector.
  2. Create "slots" for the plug-tab board to "plug" into. That way, I can have four solder points on each tab (instead of 1).
  3. Thinking about a design to support supplies that have an earth ground terminal between + and -
  4. Also, considering a barrel jack version
  5. Need some 3d-printed parts (red and black) to better indicate polarity.

image

Anyway, you can download the design files from here. But, as I said, do not build it yet! Hopefully, version two is a bit better. In the meantime, do you have any thoughts on what could be improved?

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  • jasper1000
    jasper1000 8 months ago

    I've just made my own version using similar banana plugs but with a vertical mounting USB so that I can use a single pcb. The pcb measures only 32mm x 22mm.

    image

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  • baldengineer
    baldengineer over 2 years ago in reply to Gough Lui

    It's a great idea. Mistakes happen, and an extra bit of cheap insurance could be worth it.

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  • Gough Lui
    Gough Lui over 2 years ago in reply to baldengineer

    Hmm ... as I feel your design skills may still trump mine - just wondering if you considered shoving a TVS Diode onto the back of the board?

    I'm thinking something like https://au.element14.com/bourns/smbj6-0a/diode/dp/1815172

    It's not going to be precise (it never is), but it should crowbar on reverse and also crowbar if the voltage rises excessively above 5V (6V rated reverse standoff, 7.67V maximum breakdown). It may not save a downstream device from a programming error or a power supply failure, but it might be worth it.

    Perhaps even if you don't populate it, it's still worth adding footprints for baldengineer ?

    Just my 2c from this morning - yes, I'm guilty of not thinking about safety until it's too late ...

    - Gough

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  • Gough Lui
    Gough Lui over 2 years ago in reply to baldengineer

    In that case, would it be valuable to make the current design more like a "box" by adding a top piece as well? The L shaped connection has me fearing that it is the vulnerable point, especially knowing what traces can be like to tear up on the board.

    - Gough

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  • baldengineer
    baldengineer over 2 years ago in reply to Gough Lui

    Thanks. You drew the same conclusions I did about the Multicomp. 

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