From ef9a7f40a822301c42941cec402f53a6c8a6fef3 Mon Sep 17 00:00:00 2001 From: BarnacleBoy Date: Tue, 12 May 2026 07:18:54 +0000 Subject: [PATCH] add port layout and video output decisions - Mechanical HDMI A/B switch for internal/external display toggle - DisplayLink rejected: no ARM drivers exist - 10-port layout split across 4 surfaces - Port side: 4x USB-A, 1x USB-C data, 1x USB-C PD out - Starboard: Ethernet, HDMI out, 3.5mm audio - Bow: USB-C power input + fan exhaust - Stern: handle, SD reader, Kensington lock - Updated BOM with HDMI switch, panel-mount cables, SD reader - Cost estimate now ~58 --- README.md | 10 +++++-- docs/design-decisions.md | 8 ++++++ docs/parts-list.md | 27 ++++++++++++------ docs/port-layout.md | 59 ++++++++++++++++++++++++++++++++++++++++ 4 files changed, 93 insertions(+), 11 deletions(-) create mode 100644 docs/port-layout.md diff --git a/README.md b/README.md index fa5b96f..f3538c1 100644 --- a/README.md +++ b/README.md @@ -15,6 +15,8 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC - [x] Build approach: wooden case + salvaged lid canopy - [x] Input device: ThinkPad TrackPoint keyboard - [x] Power system: IP5389 board + 18650 cells (preliminary) +- [x] Video output: mechanical HDMI A/B switch +- [x] Port layout defined (10 ports + SD reader + Kensington) - [ ] Case design (dimensions, internal layout) - [ ] Power system board selection and testing - [ ] Bow wall design (power input, fan exhaust) @@ -57,6 +59,7 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC - [Parts List](docs/parts-list.md) - Bill of materials with costs - [Design Decisions](docs/design-decisions.md) - Build approach, nomenclature, layout - [Power System](docs/power-system.md) - IP5389 battery management decision +- [Port Layout](docs/port-layout.md) - External port placement and allocation ## Quick Reference @@ -80,8 +83,9 @@ A cyberdeck built from salvaged ASUS K501U laptop components and Orange Pi 5 SBC |----------|------| | SBC | ~$104 | | Display controller | ~$24 | -| Storage (SD + hub + enclosure) | ~$32-44 | -| Power system (board + cells + fuse + charger) | ~$32-56 | -| **Subtotal** | **$206-230** | +| Storage (SD + hub + enclosure) | ~$34 | +| Power system (board + cells + fuse + charger) | ~$44 | +| HDMI switch + panel cables + SD reader | ~$33 | +| **Subtotal** | **~$258** | (Excludes case materials and misc hardware. Battery included in power system.) \ No newline at end of file diff --git a/docs/design-decisions.md b/docs/design-decisions.md index 25e2cb4..b7405ae 100644 --- a/docs/design-decisions.md +++ b/docs/design-decisions.md @@ -40,10 +40,18 @@ User sits at the **stern**, facing the **bow**. Hinge axis runs port-to-starboar - Exhaust fans blowing away from user - Heat management surface +## Carry Handle + +Stern edge (lip). Screen is lightweight, hinge is rigid, and a lid latch is planned — so the canopy-open-under-gravity concern is handled. Keeps the bow wall dedicated to power input and exhaust. + ## Power System IP5389 power bank board (preliminary). All-in-one: charging, BMS, USB-C PD output. See [power-system.md](power-system.md) for details. +## Video Output + +Mechanical HDMI A/B switch (passive, no power). Routes OPi5's single HDMI to either the internal eDP-to-HDMI controller or a panel-mount HDMI jack on the starboard side. DisplayLink doesn't work on ARM — no drivers exist. Dual simultaneous display is not possible on the base OPi5. + ## Input Device ThinkPad TrackPoint keyboard (specific model TBD based on availability). Chosen for built-in TrackPoint pointer and 15.6" deck space compatibility. diff --git a/docs/parts-list.md b/docs/parts-list.md index abb55d3..a3aa2e3 100644 --- a/docs/parts-list.md +++ b/docs/parts-list.md @@ -24,7 +24,7 @@ | Item | Specification | Source | Est. Cost | Status | |------|--------------|--------|-----------|--------| -| USB hub | Powered 7-port USB 3.0 | Amazon | $15-25 | To purchase | +| USB hub | Powered 10-port USB 3.0 | Amazon | $20-25 | To purchase | | USB enclosure | SATA 2.5" USB 3.0 | Amazon | $10-15 | To purchase | | (or) USB flash | 128GB USB 3.0 | Amazon | $15-25 | Alternative | @@ -43,7 +43,13 @@ |------|--------------|--------|-----------|--------| | WiFi dongle | USB, Linux-compatible | Amazon | $10-15 | To purchase | -### Optional +### Video & Case Integration + +| Item | Specification | Source | Est. Cost | Status | +|------|--------------|--------|-----------|--------| +| HDMI A/B switch | Mechanical, passive, bi-directional | Amazon | $8-12 | To purchase | +| Panel-mount cables | USB-A, USB-C, HDMI, Ethernet, audio | Amazon | $15-25 | To purchase | +| Panel-mount SD reader | USB 3.0 | Amazon | $5-8 | To purchase | | Item | Purpose |Source | Est. Cost | |------|---------|--------|-----------| @@ -62,20 +68,21 @@ | SBC | $104 | | Display controller | $24 | | MicroSD | $12 | -| USB hub | $20 | +| USB hub | $22 | | USB enclosure | $12 | -| Power system (board+cells+fuse+charger) | $32-56 | +| Power system (board+cells+fuse+charger) | $44 | | WiFi dongle | $12 | -| **Subtotal** | **$206-230** | +| HDMI switch | $10 | +| Panel-mount cables + SD reader | $23 | +| **Subtotal** | **$258** | ### With Optional Items | Category | Cost | |----------|------| -| Base build | $206-230 | +| Base build | $258 | | Heatsink/cooling | $10 | -| Panel-mount cables | $15 | -| **Total** | **$231-255** | +| **Total** | **$268** | ### Future Additions @@ -101,6 +108,10 @@ - IP5389 power board + 18650 cells - 5A fuse + holder - USB-C PD wall charger (45W+) +- Powered 10-port USB 3.0 hub +- Mechanical HDMI A/B switch +- Panel-mount cables (USB-A, USB-C, HDMI, Ethernet, audio) +- Panel-mount SD card reader - WiFi dongle --- diff --git a/docs/port-layout.md b/docs/port-layout.md new file mode 100644 index 0000000..5508ff6 --- /dev/null +++ b/docs/port-layout.md @@ -0,0 +1,59 @@ +# Port Layout + +## Overview + +10 accessible ports + SD reader + Kensington lock, split across four case surfaces. + +## Port Side (Left, Facing Bow) + +Data connections. "Plug and unplug frequently" zone. + +| Port | Count | Source | Notes | +|------|-------|--------|-------| +| USB-A 3.0 | 4 | Powered hub | Flash drives, peripherals, keyboard, hardware | +| USB-C (data) | 1 | Powered hub | Modern peripherals, data transfer | +| USB-C PD out | 1 | IP5389 board | Phone charging, 5V/??W | + +## Starboard Side (Right, Facing Bow) + +Networking + AV. "Plug in and leave" zone. + +| Port | Count | Source | Notes | +|------|-------|--------|-------| +| Ethernet RJ45 | 1 | OPi5 native | Gigabit, panel-mount extension | +| HDMI out | 1 | HDMI A/B switch | External display, switched from internal screen | +| 3.5mm audio out | 1 | OPi5 native | Headphones, speakers, line-out | + +## Bow Wall (Back Edge, Spine Side) + +Power and cooling. No data ports. + +| Feature | Notes | +|---------|-------| +| USB-C power input | For IP5389 board charging | +| Fan exhaust grilles | Blowing away from user | + +## Stern Edge (Front Edge, Lip) + +User-facing. Clean for typing. + +| Feature | Notes | +|---------|-------| +| Carry handle | Stern-mounted per design decision | +| SD card reader | Panel-mount, for camera cards / quick imaging | +| Kensington lock slot | Physical security | + +## Internal Components + +| Component | Connection | +|-----------|------------| +| Powered USB hub (10-port) | Decased, wired internally. Feeds all USB-A and USB-C data ports. | +| HDMI A/B switch (mechanical) | Passive toggle. OPi5 HDMI in, two outputs (internal controller + starboard panel jack). | +| eDP-to-HDMI controller | Connected to A/B switch output A. Drives internal display. | + +## Constraints + +- OPi5 has **one HDMI output**. The A/B switch selects internal or external — not both simultaneously. +- DisplayLink USB graphics adapters **do not work on ARM Linux** (no drivers). Not a viable path for dual display. +- Dual simultaneous display would require a different SBC (OPi5 Plus has 2× HDMI) or x86 board. +- USB-C on the OPi5 is power-only in this build (consumed by IP5389 board). All USB data goes through the powered hub.