Custom USB Cable Help

[Dyaems]

Hi guys. I'm currently doing a project on USB cables, because buying USB cables overseas is too darn expensive. Already built around 5 or so. Here are few examples:



While they look fine and all, I have one concern with them. They lose connectivity after some time of use. And when they lose connectivity, they're not usable anymore despite trying it on a different keyboard and keypad. It will randomly work after some time if they are not being used, but will eventually disconnect again. Not sure if I'm doing something wrong, so I need advice or suggestions. Also, I am just following the (incomplete) guide that was made here. At least the pinouts are there!

What would be the possible cause of my issue? Poor quality connectors? Poor soldering job? No connector housings? Funny enough, the cables that has a poorer soldering job and re-purposed the connectors for testing, they are the ones that lasted longer. While the ones that has a very good/near perfect solder job, and using new connectors, they do not even last a day of usage... like this thing:



The pinout is correct on that cable by the way, despite having all black wires. The next time I make a cable, I'll take a picture of the solder job as well.

I also noticed while checking some generic USB cables, they have a 5th wire that is sometimes soldered on the metal housing of the connector and is made of a single-strand of copper. Is that wire important? I do not have them on my cables.

Another thing I noticed, a couple of the USB cables I made are "installing drivers" on my computer when I connect them for the first time. Not sure what is going on but when I see that prompt, I am fairly certain that the cable will stop working after some use.


Thanks for reading and thank you in advance for any help, advice, and suggestions!

[pixelpusher]

I'm assuming you've looked over this thread:
https://geekhack.org/index.php?topic=44924.0

The single strand wire is a ground wire.  It wouldn't cause windows to try to install drivers, so something is wrong elsewhere. What gauge wire are you using in the second picture?  I can't tell from the coating.  You should be using 24/28 awg stranded wire.

Do you ever get a message saying the connection has been disabled because it needs more power?  If so, you don't have the wires in the right spot on one or both ends.  If it just fails to show up (unrecognized device), that's sometimes caused by wires touching inside the connector. 

One thing that always caused me trouble was having the stripped sections too long.  What would happen is after a few disconnects and reconnects, the cable would stop working.  I figured out it was because the wires would move inside the housing and start touching one another.  Specifically, it would usually be the white wire (on top), bending down and touching the wire below it. 



I suppose you could try to insulate the lower wires with hot glue or something, but it's really easiest just to keep the stripped wires as short as you can.  Don't leave any uninsulated wire exposed between the pad and the insulated section.  You want to butt the stripped section right up against the pad and solder.



I also had similar issues with the blue green and red wires sometimes bending and touching an adjacent wire.  Of course, you'll want to also make sure that you don't have too much solder on the pads, causing the connections to touch.

By the way, your cables look awesome!

[Dyaems]

Oh thank you for replying!

I'm assuming you've looked over this thread:
https://geekhack.org/index.php?topic=44924.0

Yes, thats the one!

The single strand wire is a ground wire.  It wouldn't cause windows to try to install drivers, so something is wrong elsewhere.

As I thought, do we also need that when making custom cables?

What gauge wire are you using in the second picture?  I can't tell from the coating.  You should be using 24/28 awg stranded wire.

Oh I have made a couple of this version, 28gauge, 24gauge, and 22gauge which is the one on that picture. I reused the 28gauge cable on the first picture.

Do you ever get a message saying the connection has been disabled because it needs more power?  If so, you don't have the wires in the right spot on one or both ends.  If it just fails to show up (unrecognized device), that's sometimes caused by wires touching inside the connector. 

No, I have not gotten any, the connection will just halt and thats about it.


One thing that always caused me trouble was having the stripped sections too long.  What would happen is after a few disconnects and reconnects, the cable would stop working.  I figured out it was because the wires would move inside the housing and start touching one another.  Specifically, it would usually be the white wire (on top), bending down and touching the wire below it. 

[ Attachment Invalid Or Does Not Exist ]

I suppose you could try to insulate the lower wires with hot glue or something, but it's really easiest just to keep the stripped wires as short as you can.  Don't leave any uninsulated wire exposed between the pad and the insulated section.  You want to butt the stripped section right up against the pad and solder.

(Attachment Link)

I also had similar issues with the blue green and red wires sometimes bending and touching an adjacent wire.  Of course, you'll want to also make sure that you don't have too much solder on the pads, causing the connections to touch.

Oh I haven't tackled this possibility that the striped (and tinned) wire is too long! Maybe this is it as I do not think I have made a cable similar to picture #2. I will do that the next time I fix one of these cables!

Oh, and I always do my best not to have too much solder on the pads.

By the way, your cables look awesome!

Thank you! Too bad they always have issues