{
  "schema": "gallery_item_v1",
  "id": "forward-200w-industrial",
  "title": "Forward · 200 W · Industrial Telecom",
  "topology": "forward",
  "blurb": "36–75 V → 12 V / 16 A RCD-clamp forward, intermediate bus DC-DC.",
  "spec": {
    "topology": "forward",
    "p_out_w": 200,
    "v_in_min": 36,
    "v_in_max": 75,
    "v_out": 12,
    "i_out_max": 16.7,
    "fsw_hz": 200000,
    "delta_t_max_c": 40,
    "isolation_v": 1500,
    "ambient_c": 25,
    "lifetime_years": 10,
    "application": "industrial",
    "rohs": true,
    "notes": "48V telecom forward 200W"
  },
  "design": {
    "spec": {
      "topology": "forward",
      "p_out_w": 200.0,
      "v_in_min": 36.0,
      "v_in_max": 75.0,
      "v_out": 12.0,
      "i_out_max": 16.7,
      "fsw_hz": 200000.0,
      "delta_t_max_c": 40.0,
      "isolation_v": 1500.0,
      "ambient_c": 25.0,
      "lifetime_years": 10.0,
      "application": "industrial",
      "rohs": true,
      "notes": "48V telecom forward 200W"
    },
    "core": {
      "pn": "RM_RM8-TDK_PC95",
      "vendor": "TDK",
      "material": "PC95",
      "shape": "RM",
      "ae_mm2": 64.0,
      "ve_mm3": 1810.0,
      "le_mm": 28.3,
      "aw_mm2": 26.0,
      "al_nh": 5158.0,
      "bsat_t_mt": {
        "25": 530.0,
        "60": 470.0,
        "100": 410.0,
        "120": 381.0
      },
      "pcv_steinmetz": {
        "k": 5.118289792176818e-08,
        "alpha": 1.42,
        "beta": 2.88,
        "t_ref_c": 100
      },
      "mu_i": 3300.0,
      "f_max_hz": 500000.0,
      "price_usd": 0.9,
      "rohs": true
    },
    "n_pri": 5,
    "n_sec": 2,
    "wire_pri": {
      "pn": "Litz_50x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 0.849,
      "od_mm": 1.002,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 50,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 1.129
    },
    "wire_sec": {
      "pn": "Litz_200x0_1_PEU",
      "vendor": "Pack Litz Wire",
      "type": "litz",
      "awg": null,
      "bare_d_mm": 1.697,
      "od_mm": 2.002,
      "insulation": "polyurethane",
      "class_c": 180,
      "breakdown_v": 2500.0,
      "litz_n": 200,
      "litz_strand_d_mm": 0.1,
      "price_usd_per_m": 4.396
    },
    "n_par_pri": 7,
    "n_par_sec": 5,
    "fringing_factor": 1.27,
    "air_gap_mm": 0.885,
    "b_peak_t": 0.3,
    "b_peak_safe": false,
    "pcv_w": 2.64,
    "pcu_w": 0.804,
    "p_total_w": 4.001,
    "eta_est": 0.9804,
    "delta_t_c": 84.7,
    "hotspot_c": 109.7,
    "lk_uh": 0.14,
    "lm_uh": 2.9,
    "cps_pf": 4.7,
    "mtbf_h": 2621531.0,
    "pdiv_v": 510.0,
    "pdiv_margin_ok": true,
    "fill_factor": 2.272,
    "bom": [
      {
        "item": "Core",
        "pn": "RM_RM8-TDK_PC95",
        "vendor": "TDK",
        "qty": 1,
        "price_usd": 0.9,
        "alternatives": []
      },
      {
        "item": "Wire-PRI",
        "pn": "Litz_50x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 1.36,
        "price_usd_per_m": 1.129
      },
      {
        "item": "Wire-SEC",
        "pn": "Litz_200x0_1_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 0.39,
        "price_usd_per_m": 4.396
      },
      {
        "item": "Bobbin",
        "pn": "BOB-RM-PBT",
        "vendor": "Pretak",
        "qty": 1,
        "price_usd": 0.6
      },
      {
        "item": "Tape",
        "pn": "3M-1350F",
        "vendor": "3M",
        "length_m": 0.5,
        "price_usd_per_m": 0.2
      },
      {
        "item": "Air-gap shim",
        "pn": "SHIM-0.88mm",
        "vendor": "internal",
        "qty": 1,
        "price_usd": 0.1
      }
    ],
    "warnings": [
      "Using 7 parallel strands of Litz_50x0_1_PEU for I_rms=10.9A.",
      "Using 5 parallel strands of Litz_200x0_1_PEU for I_rms=30.0A.",
      "Loss breakdown: Pcv=2.64W (iGSE asym-tri), Pcu=0.80W, Extras=0.56W",
      "Window overfilled: used_Ku=2.27 > target=0.30 (manual)",
      "§17 Window overfilled (effective): used_Ku=6.39 > target=0.30 (litz_manual_served, eff_area=9mm² of core.aw=26mm² — 64% lost to bobbin/margin/pins).",
      "§13.3 Dowell margin: h/δ=4.9; recommend Tier B FEM to confirm AC resistance.",
      "§13.10 Litz strand oversized: f_opt = 1277kHz vs design 200kHz; switching to thinner strands would not help — switch to solid AWG.",
      "⛔ §11.7 Lifetime 0.1y dominated by 'coffin_manson'. Below typical 5-year service requirement.",
      "§11.7 Thermal cycling dominates: ΔT=84.7°C/cycle. Reduce ΔT via better thermal management or pick more compliant potting."
    ],
    "citations": [
      "McLyman, T&I Design Handbook Ch.16 (Flyback)",
      "Self-study_Hoang.docx §2 Practices — Flyback",
      "Gemini_Claude.md §99.5"
    ],
    "trust_score": 55.0,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 15.0,
      "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": 2.9,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 2.32,
        "ci_high_2sigma": 3.48,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 0.14,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 0.084,
        "ci_high_2sigma": 0.196,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 2.64,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 1.32,
        "ci_high_2sigma": 3.96,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 0.804,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 1.608,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 109.7,
        "uncertainty_pct": 4.56,
        "ci_low_2sigma": 99.7,
        "ci_high_2sigma": 119.7,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 510.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 255.0,
        "ci_high_2sigma": 765.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 4.7,
        "uncertainty_pct": 531.91,
        "ci_low_2sigma": -45.3,
        "ci_high_2sigma": 54.7,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 2621531.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 2464239.14,
        "ci_high_2sigma": 2778822.86,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [
      "§13.3 Dowell margin: h/δ=4.9; recommend Tier B FEM to confirm AC resistance.",
      "§13.10 Litz strand oversized: f_opt = 1277kHz vs design 200kHz; switching to thinner strands would not help — switch to solid AWG."
    ],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 300,
        "mean": 131.4616,
        "stdev": 18.8934,
        "p5": 100.2872,
        "p50": 132.9962,
        "p95": 158.8177,
        "cpk_lower": 2.273,
        "cpk_upper": -2.263
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 300,
        "mean": 2.6576,
        "stdev": 0.2577,
        "p5": 2.241,
        "p50": 2.6419,
        "p95": 3.1158,
        "cpk_lower": 0.876,
        "cpk_upper": 0.831
      },
      "eta": {
        "metric": "eta",
        "n_samples": 300,
        "mean": 0.9803,
        "stdev": 0.0012,
        "p5": 0.9781,
        "p50": 0.9804,
        "p95": 0.9823,
        "cpk_lower": 2.614,
        "cpk_upper": 2.665
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 300,
        "mean": 109.6472,
        "stdev": 2.9314,
        "p5": 105.0759,
        "p50": 109.6361,
        "p95": 114.1286,
        "cpk_lower": 1.241,
        "cpk_upper": 1.253
      },
      "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": 7.2839,
        "P_classical_eddy_W_per_m3": 0.0144,
        "P_excess_W_per_m3": 1.4697,
        "P_total_W_per_m3": 8.768,
        "fraction_h": 0.8307,
        "fraction_c": 0.0016,
        "fraction_a": 0.1676,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 400000.0,
        "in_audible_band": false,
        "spl_db_estimate": 35.3,
        "lambda_s_ppm": -1.5
      },
      "aging": {
        "L_total_h": 1174.0,
        "L_total_y": 0.1,
        "dominant": "coffin_manson",
        "L_thermal_h": 2688984.0,
        "L_eyring_h": 10244.0,
        "L_coffin_manson_h": 1327.0,
        "L_ipl_h": 21139228201572.0
      },
      "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": 26.0,
      "after_walls_mm2": 38.52,
      "after_margin_mm2": 11.56,
      "after_pin_leadout_mm2": 9.25,
      "deduction_pct": 64.4,
      "wall_loss_mm2": -12.52,
      "margin_loss_mm2": 69.0,
      "margin_note": "margin tape 6.0mm × height=11.5mm",
      "pin_loss_mm2": 1.16,
      "leadout_loss_mm2": 0.58,
      "interleave_loss_mm2": 0.58,
      "bobbin_pn": "TDK_RM10_8pin",
      "ku_target": 0.3,
      "ku_key": "litz_manual_served",
      "used_ku": 6.39,
      "a_winding_mm2": 59.08
    },
    "bobbin_pn": "TDK_RM10_8pin",
    "material_score": {
      "loss": 8.5,
      "saturation": 66.9,
      "freq_fit": 93.5,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 70.0,
      "cost": 100.0,
      "availability": 100.0,
      "ap_fit": 69.6,
      "thermal": 85.2,
      "total": 67.7,
      "rationale": [
        "Pcv≈1290 mW/cm³ at design point",
        "Bsat margin=21% at 110°C",
        "fsw/f_res=0.08 (f_res≈2424kHz)",
        "no DC bias requirement",
        "f_acoustic=400000Hz outside audible",
        "industrial — flexible material choice",
        "$0.90/qty1k",
        "7 cross-vendor equivalents — supply resilient",
        "Ap ratio 3.04 much oversized",
        "Ve=1810mm³ for 200W (ratio=1.13)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "RM_RM8-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 64.0,
        "ve_mm3": 1810.0,
        "score_total": 67.7,
        "score_breakdown": {
          "loss": 8.5,
          "saturation": 66.9,
          "freq_fit": 93.5,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 100.0,
          "availability": 100.0,
          "ap_fit": 69.6,
          "thermal": 85.2
        },
        "rationale": [
          "Pcv≈1290 mW/cm³ at design point",
          "Bsat margin=21% at 110°C",
          "fsw/f_res=0.08 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=400000Hz outside audible",
          "industrial — flexible material choice",
          "$0.90/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap ratio 3.04 much oversized",
          "Ve=1810mm³ for 200W (ratio=1.13)"
        ]
      },
      {
        "pn": "RM_RM10-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 96.6,
        "ve_mm3": 4310.0,
        "score_total": 64.3,
        "score_breakdown": {
          "loss": 8.5,
          "saturation": 66.9,
          "freq_fit": 93.5,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 93.8,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈1290 mW/cm³ at design point",
          "Bsat margin=21% at 110°C",
          "fsw/f_res=0.08 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=400000Hz outside audible",
          "industrial — flexible material choice",
          "$1.62/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap ratio 8.28 much oversized",
          "Ve=4310mm³ for 200W (ratio=2.69)"
        ]
      },
      {
        "pn": "RM_RM12-TDK_PC95",
        "vendor": "TDK",
        "material": "PC95",
        "shape": "RM",
        "ae_mm2": 146.0,
        "ve_mm3": 7950.0,
        "score_total": 63.2,
        "score_breakdown": {
          "loss": 8.5,
          "saturation": 66.9,
          "freq_fit": 93.5,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 82.4,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈1290 mW/cm³ at design point",
          "Bsat margin=21% at 110°C",
          "fsw/f_res=0.08 (f_res≈2424kHz)",
          "no DC bias requirement",
          "f_acoustic=400000Hz outside audible",
          "industrial — flexible material choice",
          "$2.76/qty1k",
          "7 cross-vendor equivalents — supply resilient",
          "Ap ratio 21.30 much oversized",
          "Ve=7950mm³ for 200W (ratio=4.97)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 98.04,
    "trust_grade": "B",
    "trust_score": 55.0,
    "core_pn": "RM_RM8-TDK_PC95",
    "bobbin_pn": "TDK_RM10_8pin",
    "n_pri": 5,
    "n_sec": 2,
    "air_gap_mm": 0.885,
    "p_total_w": 4.0,
    "hotspot_c": 109.7,
    "b_peak_t": 0.3
  },
  "screenshot_path": "/marketing/gallery/forward-200w-industrial.png",
  "deep_link": "/calculator?gallery=forward-200w-industrial",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}