durable usb connections  ideas  - Page 1
Forum section: electronics / projects

author: Ehaze
author_rank: Contributor
timestamp: January 21, 2022, 09:40:00 pm
content: I use foot warmers for winter cycling , they are powered by an anker usb power pack.I made the usb cords from a cheap usb wire and some xt30 connectors , works great but its fragile . Would anyone know of some more durable options . I think the weakest point is wear the smaller usb plug wire connects to the 16awg wire . My soldering ability is that bad but it has failed twice so far .Also the usb port get a bit hot , is there any way to improve it . Im sure i could learn a bit more of the math to get the system working better , I know how to make it but not really how to calculate all the aspects of current flowTHANKS in advance !

author: BrokenYugo
author_rank: Super Contributor
timestamp: January 21, 2022, 10:13:48 pm
content: Might be helpful if you show what you've got, what's failing, etc.Between contact resistance, wire resistance of cheap cables and the boost converter in the pack, the USB plug is going to warm up some, not an issue unless we're talking burn hazard/stuff melting hot. If it's a legit Anker power bank it will shut down if you overload it.Last time I did something like this I found some heavy gauge (20 AWG) USB power pigtails, never had an issue but it was more of a proof of concept project that only left the house a couple times. e.g.https://www.ebay.com/itm/164315198928

author: Ehaze
author_rank: Contributor
timestamp: February 04, 2022, 07:14:18 am
content: So the only power source I have used for these foot warmers is these USB packs , so I just took some long usb cables and ran them down my leg to a micro usb connector. It worked but was fragile, so this time i just used some XT30 connectors and a switch and made my own cord from some old usb plugs . BUT now because the usb wires are a bit fragile it cut out a few times , because Im riding and constantly moving. For now I use some nickle strips and soldered the wire in the middle and folded it over so it have some more support . But I am looking for usb wires with some more hefty cords ....

author: tooki
author_rank: Super Contributor
timestamp: February 04, 2022, 07:41:07 am
content: Start with too-quality commercial USB cables — a USB plug you attach yourself will never be as robust as the overmolded plugs they can attach at a factory.Whatever is in constant motion needs super-flexible wire like silicone test lead wire. (There’s also industrial control cable that’s made for constant motion, like in robot arms.) But it also needs to be strain relieved really well so that strain is gently spread across a larger curve, without any sharp bends that get flexed.Can you draw a clear diagram of the setup you need?

author: Ehaze
author_rank: Contributor
timestamp: February 10, 2022, 06:30:30 am
content: Oh i never thought of Robotics parts . I made this LOL

author: tooki
author_rank: Super Contributor
timestamp: February 10, 2022, 07:52:39 am
content: Thanks, but I meant a diagram with the wiring on the human and bike.The point is to figure out what kinds of strains it’s subjected to.

author: Terry Bites
author_rank: Super Contributor
timestamp: February 10, 2022, 11:02:31 am
content: Ah jus use a big girls blowse meself.Yeh soppy begger connectors ah mekken me gidddy man.

author: Berni
author_rank: Super Contributor
timestamp: February 10, 2022, 01:19:46 pm
content: So if i understand you get the wire breaking where the solder join is.Heatshrink tubing tends to be a good solution for that. It is not only good for insulating things but it also becomes pretty rigid once shrunk so it keeps the connection from moving around too much. For the tough application you can also get heatshrink tubing with a coating of hot glue inside. Once you heat up this heatshrink it will both shrink itself down and glue itself to the wire, making it one with the tubing. This is pretty much as solid as a over molded connector.However with enough rough handling cables can start to tear and break even where the over molding ends. The fix for that can be to wrap a steel spring around the cable in that area, that spring encourages the cable to bend at more of a radius, so it is less likely to bend all it one spot and break there.