Good day,

When starting out with the IOIO I had a lot of issues regarding a reliable 
connection to the phone (Samsung galaxy S3 mini I8200 && I8190). I am using 
IOIOService to connect to and manage the IOIO and all my connected 
components. Ytai released an update to the android libraries that really 
helped but did not completely fix the issue for me. I would still on 
occasion lose connection to the board.
I figured out that I could manually recreate my issues by fiddling with the 
USB connection between the USB-OTG cable and the normal USB cable. So to 
try and avoid this I plugged the connections as normal and soldered around 
the housing of the connections so that the connection would be what I like 
to call "permanent". I also soldered the micro USB end of the cable to the 
IOIO board. This did not solve my issues unfortunately. I guess it was 
because of the way the USB connector is designed with the contacts just 
pushing down on each other.
Taking it another step further, I cut the normal USB cable connected to the 
phone on the one end. I then soldered the USB wires directly on the IOIO 
board using pads I found on the bottom (I am using the Sparkfun version of 
the board). I also bypassed the Auto/Host switch on the board so it will be 
the way I need it permanently. The only physical connection remaining now 
is the micro USB connection to the phone. This improved my disconnects 
considerably. 

I would say that I have the boards are running 95% reliable now. I do not - 
as far as I know - get any random disconnects from the board once a 
connection is established. But I have picked up a problem none the less. I 
have "hacked" the phone to startup automatically when the power is 
connected so that no user intervention will be needed and the devices can 
be in remote areas and start up when needed. The issue is that sometimes 
when the phone starts up, the connection to the IOIO is never made. My app 
also becomes very unresponsive (basically freezes) when I try to manually 
start and stop the service. When I unplug the phone from the IOIO, the app 
works fine, but plugging the phone back in does not fix my issue. It is 
like the IOIO board just locks up completely. This is the part where I'm 
kind of stuck.

I say kind of because I do have a workaround, but it is messy and I think 
there should be a way to solve this by going into the firmware of the IOIO. 
The thing is I just don't know where to start looking for or know how to 
fix the problem.

For those interested in the workaround:
I plugged in one end of an auxiliary cable to the phone and cut off the 
other end and connected it to a small circuit that uses a 1 kHz signal to 
trigger a transistor. The circuit (transistor end) is then wired back to 
the MCLR of the IOIO. When I detect that the IOIO is not connected to the 
phone, I just play the tune which resets the board and the connection comes 
back up - so far without fail.

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