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> Ethernet/RJ45 is much better without requiring thumbscrews.

I think I have more RJ45 cables with broken tabs than ones with the tabs intact. And trying to keep RJ45 in place without the tab is hopeless.

I'd rather USB cables worked for the majority of users rather than inconveniencing everyone for rare use cases.

Surely you could build some sort of retaining clip for a usb cable is you had to?

There are multiple options for locking USB connectors that retain backwards-compatibility with standard USB plugs. Amphenol and TE spring to mind and I know that there are others, including IP67 solutions.

Have you tried using one of those USB-over-CAT5 adapters they sell on eBay? I've always wanted to but never had a real application for it, and robotics sound perfect. Just bolt down the adapter on one side.