BarnacleBoy 8b41038be7 Initial commit: cyberdeck project planning docs

- Salvage analysis of K501U components
- Orange Pi 5 SBC selection rationale
- Storage architecture (SD card + USB)
- USB hub expansion plan
- Parts list and cost estimates

2026-05-08 22:48:30 +00:00

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USB Port Expansion

Goal: Multiple USB ports for cyberdeck peripherals

Native Ports (Orange Pi 5)

Port	Type	Speed	Location
USB 3.0	Type-A	5 Gbps	Board edge
USB 2.0× Type-A	480 Mbps	Board edge
USB-C	Power + DisplayPort	5 Gbps	Power input

Total native USB: 3 ports (1× USB 3.0, 2× USB 2.0)

This is insufficient for a cyberdeck with multiple peripherals.

USB Hub Solution

Why Powered Hub

Hub Type	Power Source	Issues
Bus-powered	Draws from OPi5	Voltage drops, instability
Self-powered	External 5V supply	Stable, reliable

Orange Pi 5 USB power budget: ~900mA total across all ports.

Device power draw:

Device	Draw
USB SSD	500-1000mA
WiFi dongle	200-500mA
Keyboard	50-100mA
Mouse	50-100mA
Webcam	250-500mA

Conclusion: Bus-powered hub will cause brownouts. Use powered hub.

Hub Options

Consumer-Grade

Model	Ports	Power	Cost
Sabrent 7-Port USB 3.0	4× 3.0 + 3× 2.0	Barrel jack	$20-25
Anker 7-Port USB 3.0	7× 3.0	Barrel jack	$25-30
Anker 4-Port USB 3.0	4× 3.0	Barrel jack	$15-20

Industrial

Model	Ports	Power	Cost
USB Hub PCB (GL850G)	4× 2.0	External 5V	$8-12
Industrial USB 3.0 Hub	4-7× 3.0	External 5V	$15-30

Recommendation

Sabrent 7-Port USB 3.0 Powered Hub

4× USB 3.0 + 3× USB 2.0
External 5V barrel jack
Vertical orientation (compact)
~$20-25

Connection Diagram

                    ┌─────────────────┐
                    │  Orange Pi 5    │
                    │                 │
                    │  USB 3.0 ───────┼─────┐
                    │  USB 2.0 ───────┼──┐  │
                    │  USB 2.0 ───────┼──┼─┐│
                    │                 │  │ ││
                    └─────────────────┘  │ ││
                                         │ ││
                    ┌────────────────────┘ ││
                    │                      ││
                    ▼                      ││
         ┌─────────────────────┐          ││
         │  Powered USB Hub    │          ││
         │  (7-port)           │          ││
         │                     │          ││
         │  [Uplink] ◀─────────┘          ││
         │                     │          ││
         │  [1] [2] [3] [4]    │          ││
         │  [5] [6] [7]        │          ││
         │                     │          ││
         │  ┌─────────┐        │          ││
         │  │ 5V DC   │◄───────┼──────────┼┼── external power
         │  └─────────┘        │          ││
         └─────────────────────┘          ││
                    │                     ││
                    ▼                     ││
         ┌─────────────────────┐          ││
         │  Peripherals        │          ││
         │  • SSD enclosure    │          ││
         │  • WiFi dongle      │          ││
         │  • Keyboard/mouse   │          ││
         │  • Webcam           │          ││
         │  • Misc USB         │          ││
         └─────────────────────┘          ││
                                         ││
         Native ports still available:   ││
         • 2× USB 2.0 (keyboard, mouse) ◄─┘│
         • 1× USB-C (power input)       ◄──┘

Port Allocation

After Hub

Port	Location	Purpose	Speed
Hub Port 1	Hub	USB SSD	5 Gbps
Hub Port 2	Hub	Data transfer	5 Gbps
Hub Port 3	Hub	Data transfer	5 Gbps
Hub Port 4	Hub	Data transfer	5 Gbps
Hub Port 5	Hub	WiFi dongle	480 Mbps
Hub Port 6	Hub	Bluetooth dongle	480 Mbps
Hub Port 7	Hub	Misc peripheral	480 Mbps
Native USB 2.0	OPi5	Keyboard	480 Mbps
Native USB 2.0	OPi5	Mouse	480 Mbps

Total available: 9 ports (7 from hub + 2 native USB 2.0)

Estimated Usage for Cyberdeck

1× USB SSD (data storage)
1× WiFi dongle
1× Keyboard
1× Mouse
1× Webcam (optional)
4× Expansion ports

Panel-Mount Options

For a permanent cyberdeck build, mount USB ports on the case face.

Method 1: Panel-Mount Cables

Pre-made cables with panel-mount USB-A connectors:

Panel mount USB-A extension (~$10-15 for 4-pack)
Panel mount USB-C (~$10-15 for 2-pack)

Setup:

Mount connectors in case face
Run cables inside to hub
Secure hub internally

Method 2: Industrial Hub PCB

Bare hub PCB designed for integration:

Mount PCB inside case
Wire panel connectors directly to PCB
Cleaner internal layout

Parts:

USB hub PCB (GL850G or similar): $8-15
Panel-mount USB connectors: $10-15
Meanwell 5V 3A PSU: $8

Total: ~$25-35

Power Considerations

Hub Power Requirements

Specification	Value
Input voltage	5V DC
Current	2-4A (depending on devices)
Connector	Barrel jack (usually)

Powering the Hub

Method	Notes
Wall adapter (included)	Simple, separate power brick
5V from cyberdeck PSU	Integrated, requires 5V rail
USB-C PD	Requires USB-C hub with PD pass-through

Power Budget

Component	Draw
Orange Pi 5 (16GB)	5-8W
USB hub (self-powered)	1-2W
USB SSD	2-4W
Peripherals	1-2W
Total	9-16W

For portable build: 10,000-20,000 mAh battery pack with PD output.

GPIO Alternative

USB hubs do not require GPIO.

GPIO (26-pin header) is for:

Serial console (TX/RX)
I2C devices (sensors, displays)
SPI devices (LCD, flash)
PWM (fan speed, servos)
Digital I/O (buttons, LEDs)

If you want internal hub without USB cable:

Use GPIO for power only (5V/GND)
Still need USB data connection

Cost Summary

Item	Cost
Powered USB 3.0 hub (7-port)	$15-25
Panel-mount cables (optional)	$10-20
Total	$15-45

Recommended First Iteration

Buy Sabrent 7-port powered hub ($20)
Plug into Orange Pi 5 USB 3.0 port
Use external power adapter
Done — no custom wiring needed

When you're ready for permanent build:

Removehub from plastic case
Mount PCB inside cyberdeck
Wire panel-mount connectors
Power from internal 5V rail

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