I have a rather excessive number of laptops, at the moment my three main ones are a rather ancient Lenovo T430 (personal), a Lenovo X1 Gen4, and a Chromebook Pixel 2 (both work).
At the start of last year I had a T430s in place of the X1, and was planning on replacing both it and my personal ThinkPad mid-year. However both of those older laptops used Lenovo's long-held (back to the IBM days) barrel charger, which lead to me having a heap of them in various locations at home and work, but all the newer machines switched to their newer rectangular "slim" style power connector and while adapters exist, I decided to go in a different direction.
One of the less-touted features of USB-C is USB-PD, which allows devices to be fed up to 100W of power, and can do so while using the port for data (or the other great feature of USB-C, alternate modes, such as DisplayPort, great for docks), which is starting to be used as a way to charge laptops, such as the Chromebook Pixel 2, various models of the Apple MacBook line, and more.
Instead of buying a heap of slim-style Lenovo chargers, or a load of adapters (which would inevitably disappear over time) I decided to bridge towards the future by making an adapter to allow me to charge slim-type ThinkPads (at least the smaller ones, not the portable workstations which demand 120W or more).
After doing some research on what USB-PD platforms were available at the time I settled on the TI TPS65986 chip, which, with only an external flash chip, would do all that I needed.
Devkits were ordered to experiment with, and prove the concept, which they did very quickly, so I started on building the circuit, since just reusing the devkit boards would lead to an adapter larger than would be sensible. As the TI chip is a many-pin BGA, and breaking it out on 2-layers would probably be too hard for my meager PCB design skills, I needed a 4-layer board, so I decided to use KiCad for the project.
It took me about a week of evenings to get the schematic fully sorted, with much of the time spent reading the chip datasheet, or digging through the devkit schematic to see what they did there for some cases that weren't clear, then almost a month for the actual PCB layout, with much of the time being sucked up learning a tool that was brand new to me, and also fairly obtuse.
By mid-June I had a PCB which should (but, spoiler, wouldn't) work, however as mentioned the TI chip is a 96-ball 3x3mm BGA, something I had no hope of manually placing for reflow, and of course, no hope of hand soldering, so I would need to get these manufactured commercially. Luckily there are several options for small scale assembly at very reasonable prices, and I decided to try a new company still (at the time of ordering) in closed trials, PCB.NG, they have a nice simple procedure to upload board files, and a slightly custom pick & place file that includes references to the exact component I want by Digikey[link] part number. Best of all the pricing was completely reasonable, with a first test run of six boards only costing my US$30 each.
Late in June I recieved a mail from PCB.NG telling me that they'd built my boards, but that I had made a mistake with the footprint I'd used for the USB-C connector and they were posting my boards along with the connectors. As I'd had them ship the order to California (at the time they didn't seem to offer international shipping) it took a while for them to arrive in Sydney, courtesy a coworker.
I tried to modify a connector by removing all through hole board locks, keeping just the surface mount pins, however I was unsuccessful, and that's where the project stalled until mid-October when I was in California myself, and was able to get help from a coworker who can perform miracles of surface mount soldering (while they were working on my board they were also dead-bug mounting a BGA). Sadly while I now had a board I could test it simply dropped off my priority list for months.
At the start of January another of my colleagues (a US-based teammate of the London rabble-rousers) asked for a status update, which prompted me to get off my butt and perform the testing. The next day I added some reinforcement to the connector which was only really held on by the surface mount pins, and was highly likely to rip off the board, so I covered it in epoxy. Then I knocked up some USB A plug/socket to bare wires test adapters using some stuff from the junk bin we have at the office maker space for just this sort of occasion (the socket was actually a front panel USB port from an old IBM x-series server). With some trepidation I plugged the board into my newly built & tested adapter, and powered the board from a lab supply set to limit current in case I'd any shorts in the board. It all came up straight away, and even lit the LEDs I'd added for some user feedback.
Next was to load a firmware for the chip. I'd previously used TI's tool to create a firmware image, and after some messing around with the SPI flash programmer I'd purchased managed to get the board programmed. However the behaviour of the board didn't change with (what I thought was) real firmware, I used an oscilloscope to verify the flash was being read, and a twinkie to sniff the PD negotiation, which confirmed that no request for 20v was being sent. This was where I finished that day.
Over the weekend that followed I dug into what I'd seen and determined that either I'd killed the SPI MISO port (the programmer I used was 5v, not 3.3v), or I just had bad firmware and the chip had some good defaults. I created a new firmware image from scratch, and loaded that.
Sure enough it worked first try. Once I confirmed 20v was coming from the output ports I attached it to my recently acquired HP 6051A DC load where it happily sank 45W for a while, then I attached the cable part of a Lenovo barrel to slim adapter and plugged it into my X1 where it started charging right away.
At linux.conf.au last week I gave (part of) a hardware miniconf talk about USB-C & USB-PD, which open source hardware folk might be interested in. Over the last few days while visiting my dad down in Gippsland I made the edits to fix the footprint and sent a new rev to the manufacturer for some new experiments.
Of course at CES Lenovo announced that this years ThinkPads would feature USB-C ports and allow charging through them, and due to laziness I never got around to replacing my T430, so I'm planning to order a T470 as soon as they're available, making my adapter obsolete.
- April 21st 2016, decide to start working on the project
- April 28th, devkits arrive
- May 8th, schematic largely complete, work starts on PCB layout
- June 14th, order sent to CM
- ~July 6th, CM ships order to me (to California, then hand carried to me by a coworker)
- early August, boards arrive from California
- Somewhere here I try, and fail, to reflow a modified connector onto a board
- October 13th, California cowoker helps to (successfully) reflow a USB-C connector onto a board for testing
- January 6th 2017, finally got around to reinforce the connector with epoxy and started testing, try loading firmware but no dice
- January 10th, redo firmware, it works, test on DC load, then modify a ThinkPad-slim adapater and test on a real ThinkPad
- January 25/26th, fixed USB-C connector footprint, made one more minor tweak, sent order for rev2 to CM, then some back & forth over some tolerance issues they're now stricter on.
1: There's a previous variant of USB-PD that works on the older A/B connector, but, as far as I'm aware, was never implemented in any notable products.