{
  "schema": "gallery_item_v1",
  "id": "cm-choke-line",
  "title": "Common-Mode Choke · 1 mH / 6 A",
  "topology": "cm_choke",
  "blurb": "Bifilar nanocrystalline CM choke for EMI line filter, Snoek-bounded.",
  "spec": {
    "topology": "cm_choke",
    "p_out_w": 1000,
    "v_in_min": 220,
    "v_in_max": 240,
    "v_out": 240,
    "i_out_max": 6.0,
    "fsw_hz": 150000,
    "delta_t_max_c": 30,
    "isolation_v": 1500,
    "ambient_c": 40,
    "lifetime_years": 10,
    "application": "industrial",
    "rohs": true,
    "notes": "Line CM choke 1mH @ 150kHz, 6A AC"
  },
  "design": {
    "spec": {
      "topology": "cm_choke",
      "p_out_w": 1000.0,
      "v_in_min": 220.0,
      "v_in_max": 240.0,
      "v_out": 240.0,
      "i_out_max": 6.0,
      "fsw_hz": 150000.0,
      "delta_t_max_c": 30.0,
      "isolation_v": 1500.0,
      "ambient_c": 40.0,
      "lifetime_years": 10.0,
      "application": "industrial",
      "rohs": true,
      "notes": "Line CM choke 1mH @ 150kHz, 6A AC"
    },
    "core": {
      "pn": "Toroid_TX25_15_10-Ferroxcube_3E27",
      "vendor": "Ferroxcube",
      "material": "3E27",
      "shape": "Toroid",
      "ae_mm2": 49.5,
      "ve_mm3": 3110.0,
      "le_mm": 62.9,
      "aw_mm2": 132.7,
      "al_nh": 3263.5,
      "bsat_t_mt": {
        "25": 380.0,
        "60": 330.0,
        "100": 280.0,
        "120": 260.0
      },
      "pcv_steinmetz": {
        "k": 5.4485755041330205e-06,
        "alpha": 1.55,
        "beta": 2.5,
        "t_ref_c": 100
      },
      "mu_i": 6000.0,
      "f_max_hz": 100000.0,
      "price_usd": 1.07,
      "rohs": true
    },
    "n_pri": 13,
    "n_sec": 13,
    "wire_pri": {
      "pn": "Litz_50x0_071_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 0.602,
      "od_mm": 0.71,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 50,
      "litz_strand_d_mm": 0.071,
      "price_usd_per_m": 0.837
    },
    "wire_sec": {
      "pn": "Litz_50x0_071_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 0.602,
      "od_mm": 0.71,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 50,
      "litz_strand_d_mm": 0.071,
      "price_usd_per_m": 0.837
    },
    "n_par_pri": 8,
    "n_par_sec": 8,
    "fringing_factor": 1.0,
    "air_gap_mm": 0.0,
    "b_peak_t": 0.05,
    "b_peak_safe": true,
    "pcv_w": 0.05,
    "pcu_w": 0.24,
    "p_total_w": 0.29,
    "eta_est": 0.9997,
    "delta_t_c": 4.6,
    "hotspot_c": 44.6,
    "lk_uh": 5.0,
    "lm_uh": 1000.0,
    "cps_pf": 10.0,
    "mtbf_h": 238490739.0,
    "pdiv_v": 522.0,
    "pdiv_margin_ok": false,
    "fill_factor": 0.621,
    "bom": [
      {
        "item": "Core",
        "pn": "Toroid_TX25_15_10-Ferroxcube_3E27",
        "vendor": "Ferroxcube",
        "qty": 1,
        "price_usd": 1.07
      },
      {
        "item": "Wire (bifilar)",
        "pn": "Litz_50x0_071_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 4.1,
        "price_usd_per_m": 0.837
      },
      {
        "item": "Tape",
        "pn": "3M-1350F",
        "vendor": "3M",
        "length_m": 0.3,
        "price_usd_per_m": 0.2
      }
    ],
    "warnings": [
      "Using 8 parallel strands of Litz_50x0_071_PEU for I_rms=6.0A.",
      "Window overfilled: used_Ku=0.62 > target=0.30 (manual)",
      "PDIV margin 0.35x < 1.5x (PDIV=522V vs Vpeak=1500V). Recommend potting (silicone) or thicker insulation / TIW.",
      "Bus≥600V with thin standard insulation: HIGH PDIV RISK (Gemini §99.5).",
      "§17 Window overfilled (effective): used_Ku=0.62 > target=0.30 (litz_manual_served, eff_area=133mm² of core.aw=133mm² — 0% lost to bobbin/margin/pins).",
      "§17 fit_check_v2: NO bobbin spec — used core.aw_mm2 directly. First-pass success risk +30%. Specify bobbin_pn or use planar/toroid.",
      "§13.10 Litz strand oversized: f_opt = 2055kHz vs design 150kHz; switching to thinner strands would not help — switch to solid AWG."
    ],
    "citations": [
      "McLyman Ch.8 (CM choke)",
      "IEC 61000-6-2 EMC",
      "Self-study §2"
    ],
    "trust_score": 60.0,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 20.0,
      "reference_benchmark": 8.0,
      "datasheet_match": 12.0,
      "lab_measurement": 0.0
    },
    "trust_grade": "B",
    "reliability_matrix": {
      "Lm_pct": 10.0,
      "Lk_pct": 20.0,
      "Pcv_in_range_pct": 25.0,
      "Pcv_dc_bias_pct": 50.0,
      "Rac_near_gap_pct": 50.0,
      "T_hotspot_C": 5.0,
      "EMI_Cps_pct": null,
      "PDIV_margin_pct": null,
      "lifetime_factor": 3.0
    },
    "not_valid_for": [
      "UL 1446 insulation system certification",
      "IEC 61558 / 62368 transformer certification",
      "AEC-Q200 automotive component qualification",
      "CISPR 22/32 EMI compliance claim",
      "Lifetime claim > 5 years without HALT calibration"
    ],
    "uncertainty_envelope": {
      "Lm_uH": {
        "value": 1000.0,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 800.0,
        "ci_high_2sigma": 1200.0,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 5.0,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 3.0,
        "ci_high_2sigma": 7.0,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 0.05,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 0.025,
        "ci_high_2sigma": 0.075,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 0.24,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 0.48,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 44.6,
        "uncertainty_pct": 11.21,
        "ci_low_2sigma": 34.6,
        "ci_high_2sigma": 54.6,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 522.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 261.0,
        "ci_high_2sigma": 783.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 10.0,
        "uncertainty_pct": 250.0,
        "ci_low_2sigma": -40.0,
        "ci_high_2sigma": 60.0,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 238490739.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 224181294.66,
        "ci_high_2sigma": 252800183.34,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [
      "§13.10 Litz strand oversized: f_opt = 2055kHz vs design 150kHz; switching to thinner strands would not help — switch to solid AWG."
    ],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 300,
        "mean": 560.6995,
        "stdev": 79.4361,
        "p5": 434.9264,
        "p50": 569.0883,
        "p95": 680.7894,
        "cpk_lower": -1.424,
        "cpk_upper": 2.263
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 300,
        "mean": 0.0503,
        "stdev": 0.0045,
        "p5": 0.043,
        "p50": 0.0499,
        "p95": 0.0581,
        "cpk_lower": 0.953,
        "cpk_upper": 0.915
      },
      "eta": {
        "metric": "eta",
        "n_samples": 300,
        "mean": 0.9997,
        "stdev": 0.0,
        "p5": 0.9997,
        "p50": 0.9997,
        "p95": 0.9997,
        "cpk_lower": 748.175,
        "cpk_upper": 746.705
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 300,
        "mean": 44.5386,
        "stdev": 2.938,
        "p5": 40.0239,
        "p50": 44.5155,
        "p95": 49.1106,
        "cpk_lower": 0.499,
        "cpk_upper": 0.513
      },
      "preset": {
        "al_nh_pct": 25.0,
        "gap_mm_abs": 0.05,
        "b_pk_pct": 5.0,
        "steinmetz_k_pct": 10.0
      }
    },
    "llc_tank": {},
    "inrush": {},
    "advanced_analysis": {
      "bertotti": {
        "P_hysteresis_W_per_m3": 0.3107,
        "P_classical_eddy_W_per_m3": 0.0002,
        "P_excess_W_per_m3": 0.065,
        "P_total_W_per_m3": 0.3759,
        "fraction_h": 0.8266,
        "fraction_c": 0.0006,
        "fraction_a": 0.1728,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 300000.0,
        "in_audible_band": false,
        "spl_db_estimate": 19.7,
        "lambda_s_ppm": -1.5
      },
      "aging": {
        "L_total_h": 314656.0,
        "L_total_y": 35.9,
        "dominant": "eyring",
        "L_thermal_h": 207753932.0,
        "L_eyring_h": 377222.0,
        "L_coffin_manson_h": 1930232.0,
        "L_ipl_h": 236915030.0
      },
      "paschen": {
        "v_breakdown": 12594.0,
        "altitude_derating": 1.0,
        "safe": true
      },
      "humidity": {
        "moisture_uptake_pct": 0.118,
        "pdiv_derate_pct": 0.6,
        "aging_factor": 1.006,
        "safe": true
      }
    },
    "window_breakdown": {
      "core_window_mm2": 132.7,
      "after_walls_mm2": 132.7,
      "after_margin_mm2": 132.7,
      "after_pin_leadout_mm2": 132.7,
      "deduction_pct": 0.0,
      "warning": "no bobbin spec; using core.aw_mm2 directly",
      "ku_target": 0.3,
      "ku_key": "litz_manual_served",
      "used_ku": 0.621,
      "a_winding_mm2": 82.35
    },
    "bobbin_pn": "",
    "material_score": {
      "loss": 91.2,
      "saturation": 100.0,
      "freq_fit": 100.0,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 70.0,
      "cost": 50.0,
      "availability": 100.0,
      "ap_fit": 53.7,
      "thermal": 100.0,
      "total": 87.1,
      "rationale": [
        "Pcv≈83 mW/cm³ at design point",
        "Bsat margin=95% at 45°C",
        "fsw/f_res=0.00 (f_res≈133333kHz)",
        "no DC bias requirement",
        "f_acoustic=300000Hz outside audible",
        "industrial — flexible material choice",
        "$8.34/qty1k",
        "4 cross-vendor equivalents — supply resilient",
        "Ap ratio 4.63 much oversized",
        "Ve=13400mm³ for 1000W (ratio=1.68)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "Magnetics_55310-Magnetics_KoolMu_60u",
        "vendor": "Magnetics Inc",
        "material": "KoolMu-60u",
        "shape": "Toroid",
        "ae_mm2": 217.0,
        "ve_mm3": 13400.0,
        "score_total": 87.1,
        "score_breakdown": {
          "loss": 91.2,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 50.0,
          "availability": 100.0,
          "ap_fit": 53.7,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈83 mW/cm³ at design point",
          "Bsat margin=95% at 45°C",
          "fsw/f_res=0.00 (f_res≈133333kHz)",
          "no DC bias requirement",
          "f_acoustic=300000Hz outside audible",
          "industrial — flexible material choice",
          "$8.34/qty1k",
          "4 cross-vendor equivalents — supply resilient",
          "Ap ratio 4.63 much oversized",
          "Ve=13400mm³ for 1000W (ratio=1.68)"
        ]
      },
      {
        "pn": "Micrometals_T130-Micrometals_26",
        "vendor": "Micrometals",
        "material": "Material -26",
        "shape": "Toroid",
        "ae_mm2": 73.2,
        "ve_mm3": 5710.0,
        "score_total": 86.6,
        "score_breakdown": {
          "loss": 81.3,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 82.3,
          "availability": 100.0,
          "ap_fit": 100.0,
          "thermal": 57.1
        },
        "rationale": [
          "Pcv≈120 mW/cm³ at design point",
          "Bsat margin=96% at 45°C",
          "fsw/f_res=0.00 (f_res≈106667kHz)",
          "no DC bias requirement",
          "f_acoustic=300000Hz outside audible",
          "industrial — flexible material choice",
          "$2.77/qty1k",
          "6 cross-vendor equivalents — supply resilient",
          "Ap ratio 1.03 optimal",
          "Ve=5710mm³ for 1000W (ratio=0.71)"
        ]
      },
      {
        "pn": "Magnetics_55310-Magnetics_MPP_60u",
        "vendor": "Magnetics Inc",
        "material": "MPP-60u",
        "shape": "Toroid",
        "ae_mm2": 217.0,
        "ve_mm3": 13400.0,
        "score_total": 86.5,
        "score_breakdown": {
          "loss": 100.0,
          "saturation": 100.0,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 25.9,
          "availability": 100.0,
          "ap_fit": 53.7,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈40 mW/cm³ at design point",
          "Bsat margin=93% at 45°C",
          "fsw/f_res=0.00 (f_res≈133333kHz)",
          "no DC bias requirement",
          "f_acoustic=300000Hz outside audible",
          "industrial — flexible material choice",
          "$16.38/qty1k",
          "4 cross-vendor equivalents — supply resilient",
          "Ap ratio 4.63 much oversized",
          "Ve=13400mm³ for 1000W (ratio=1.68)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 99.97,
    "trust_grade": "B",
    "trust_score": 60.0,
    "core_pn": "Toroid_TX25_15_10-Ferroxcube_3E27",
    "bobbin_pn": "",
    "n_pri": 13,
    "n_sec": 13,
    "air_gap_mm": 0.0,
    "p_total_w": 0.29,
    "hotspot_c": 44.6,
    "b_peak_t": 0.05
  },
  "screenshot_path": "/marketing/gallery/cm-choke-line.png",
  "deep_link": "/calculator?gallery=cm-choke-line",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}