this post was submitted on 01 Mar 2025
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Barrel jacks were awesome, they could go in any orientation. The only downside was the many different forms of barrel jack and lack of a standard. My question is: why isn't there a cylindrical USB port? You would be able to rotate it any way you want within 360 degrees!

As a matter of fact, why isn't there a cylindrical power plug? You'd get the benefits of a recessed plug like Type-C (EU) and Type-F (Schuko), you'd get the benefits of reversible plugs like Type-A (North American) and more so as you get 360-degree rotation, and it would be MUCH harder to break/bend compared to two flimsy pins (the UK plug has three thicker pins, but a chunky cylinder would be much more difficult to bend than the pins)

If it was a hollow cylinder (a bit like a vacuum-insulated water bottle), you could feasibly fit some small electronics in it, so things like flush low-power USB chargers and smart home sensors could be made.

The contacts would likely need to be outside the cylinder, similar to the "neutral" pins on Schuko plugs. There would likely need to be some plastic tabs to keep the power bits from touching the non-power bits, and then the socket itself would be able to freely rotate.

Actually, why don't regular sockets freely rotate? Then it would solve all the issues of non-reversible plugs not able to go upside down and reversible plugs not able to go sideways.

Speaking of cylindrical objects, what happened to camcorders? They sound like the most comfortable and easiest way to record videos, with straps and everything. They were compact, portable, and wasn't heavy as all heck.

this is my rant about cylinders, thank you for your time.

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[–] [email protected] 34 points 1 day ago (14 children)

A cylindrical connector would be fine for connecting one or two conductors. But more than that and it starts to become a nightmare to design, and even worse to build and use reliably. Classic examples include the venerable RCA connector, the BNC connector for radio signals, and IMO the worst connector to ever exist, the F-type connector used for TV coaxial cable.

With just two conductors, a cylinder can have have a concentric shape, where the inside is a pin and the outside is a shell. But you'll notice that although all these connectors are circular, they're hardly designed to rotate while attached. You generally have to remove or at least loosen them before trying to turn them. Or you still try it and the TV picture might flicker a bit. The problem is one of electrical contact.

The engineers that make connectors go through painstaking efforts to get the conductive surfaces to align -- or "mate" as they say -- because if they don't, the signal quality drops like a rock. It's already hard enough to get cheap connectors to reliably align, but now you want them to move relative to each other? That's tough to build, and moving surfaces will eventually wear down.

Even worse is that circular shapes tend to have poorer mating, because manufacturing tolerances for curves is wider than tolerances for flat surfaces. We actually don't want to make round contacts, if a rectangular shape would suffice. Flat contacts are simpler to produce and generally more reliable [citation needed].

But even more intractable is the matter of matching the pinouts. Here is the pinout when looking at the connector of a USB C cord:

USB C pinout when looking straight at a USB C cord

Even without understanding what each pin does, it's noticeable that certain pins are the same whether you flip the connector over. In fact, they even label them that way: pin A12 on the top-right is also B12 on the bottom-left. The most damaging scenario is if USB 5v power was sent down the wrong pin, but it's very clear that the VBUS pins -- which are the 5v power -- will always be in the same place no matter the cord orientation.

The only pins which are different upon inversion are the data lines -- anything with a + or - in the name -- or certain control signals which are intentionally paired with their opposite signal (eg CC1 and CC2). The USB C designers could have packed way more data pins if they didn't have to duplicate half the pins to allow flipping the connector over. But that design choice has made USB C easier to use. A fair tradeoff.

And that's the crux of it: in engineering, we are always dealing with tradeoffs, either for performance, cost to produce, ease of use, future compatibility, and a host of other concerns. Wanting a cylindrical connector could certainly be a design goal. But once it starts causing problems with alignment or manufacturing, there will inevitably be pushback. And it's clear that of all the popular connectors used today, few are cylindrical.

Heck, even for DC power, the barrel connector has given way to more popular designs, like the Anderson PowerPole or the XT family of connectors, because the market needed high-current connectors for drones and Li-po batteries. Granted, the XT connectors are basically two cylindrical connectors side-by-side haha.

[–] [email protected] 7 points 1 day ago (1 children)

woah that’s a very in-depth answer. yeah makes sense that cylindrical connectors aren’t actually designed to rotate a bunch. I assume it would be something similar to weird crackling sound when you turn an 3.5mm jack cable too hard?

[–] [email protected] 7 points 1 day ago* (last edited 1 day ago)

I'm not sure how hard you're rotating a 3.5 mm cable, but yes, that sound is the sudden making and breaking of the contacts, which it's not meant to do. It will wear down the surfaces, even if the 3.5 mm tip is gold plated, since the gold is for anti-corrosion not for anti-friction.

But, the notion of cylinder housings for connectors has not died. After all, large cylinders are easy to grasp. Here is one very beefy example, often called the California Standard connector due to its use for Hollywood movie productions. This is a waterproof, twist-lock connector that also suppresses arcs if you unplug it while it's still on. It can only connect in one orientation, so you keep rotating around the center pin until it slots in. It's heavy enough to probably also double as a blackjack for self-defense lol

Hubbel California standard connectors CS6365 and CS6364

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