{
  "schema": "gallery_item_v1",
  "id": "pfc-500w",
  "title": "PFC Boost Choke · 500 W",
  "topology": "pfc_choke",
  "blurb": "Universal-AC boost PFC choke, MPP powder core, line-frequency envelope.",
  "spec": {
    "topology": "pfc_choke",
    "p_out_w": 500,
    "v_in_min": 90,
    "v_in_max": 264,
    "v_out": 400,
    "i_out_max": 1.25,
    "fsw_hz": 100000,
    "delta_t_max_c": 50,
    "isolation_v": 0,
    "ambient_c": 40,
    "lifetime_years": 10,
    "application": "industrial",
    "rohs": true,
    "notes": "Boost PFC, universal AC input, 500W"
  },
  "design": {
    "spec": {
      "topology": "pfc_choke",
      "p_out_w": 500.0,
      "v_in_min": 90.0,
      "v_in_max": 264.0,
      "v_out": 400.0,
      "i_out_max": 1.25,
      "fsw_hz": 100000.0,
      "delta_t_max_c": 50.0,
      "isolation_v": 0.0,
      "ambient_c": 40.0,
      "lifetime_years": 10.0,
      "application": "industrial",
      "rohs": true,
      "notes": "Boost PFC, universal AC input, 500W"
    },
    "core": {
      "pn": "Magnetics_55121-Magnetics_MPP_60u",
      "vendor": "Magnetics Inc",
      "material": "MPP-60u",
      "shape": "Toroid",
      "ae_mm2": 65.4,
      "ve_mm3": 4290.0,
      "le_mm": 65.7,
      "aw_mm2": 169.71668912855458,
      "al_nh": 41.3,
      "bsat_t_mt": {
        "25": 750.0,
        "60": 745.0,
        "100": 740.0,
        "120": 688.0
      },
      "pcv_steinmetz": {
        "k": 5.248074602497723e-06,
        "alpha": 1.46,
        "beta": 2.18,
        "t_ref_c": 100
      },
      "mu_i": 60.0,
      "f_max_hz": 1000000.0,
      "price_usd": 5.45,
      "rohs": true
    },
    "n_pri": 79,
    "n_sec": 0,
    "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": 0,
    "fringing_factor": 1.555,
    "air_gap_mm": 1.614,
    "b_peak_t": 0.8,
    "b_peak_safe": false,
    "pcv_w": 3.2,
    "pcu_w": 1.431,
    "p_total_w": 5.195,
    "eta_est": 0.9897,
    "delta_t_c": 69.0,
    "hotspot_c": 109.0,
    "lk_uh": 0.0,
    "lm_uh": 494.2,
    "cps_pf": 0.0,
    "mtbf_h": 2748857.0,
    "pdiv_v": 540.0,
    "pdiv_margin_ok": false,
    "fill_factor": 1.474,
    "bom": [
      {
        "item": "Core",
        "pn": "Magnetics_55121-Magnetics_MPP_60u",
        "vendor": "Magnetics Inc",
        "qty": 1,
        "price_usd": 5.45
      },
      {
        "item": "Wire",
        "pn": "Litz_50x0_071_PEU",
        "vendor": "Pack Litz Wire",
        "length_m": 20.64,
        "price_usd_per_m": 0.837
      },
      {
        "item": "Bobbin",
        "pn": "BOB-Toroid",
        "vendor": "Pretak",
        "qty": 1,
        "price_usd": 0.5
      },
      {
        "item": "Air-gap shim",
        "pn": "SHIM-1.61mm",
        "vendor": "internal",
        "qty": 1,
        "price_usd": 0.1
      }
    ],
    "warnings": [
      "Using 8 parallel strands of Litz_50x0_071_PEU for I_rms=5.8A.",
      "⚠️ DC-bias rolloff: μ_e/μ_i=0.25 at H=9944A/m. Inductance droop > 50%. Consider larger core or distributed-gap material.",
      "Loss breakdown: Pcv=3.20W, Pcu=1.43W, Extras=0.56W",
      "Window overfilled: used_Ku=1.47 > target=0.30 (manual)",
      "PDIV margin 1.35x < 1.5x (PDIV=540V vs Vpeak=400V). Recommend potting (silicone) or thicker insulation / TIW.",
      "§17 Window overfilled (effective): used_Ku=1.47 > target=0.30 (litz_manual_served, eff_area=170mm² of core.aw=170mm² — 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.",
      "⛔ §13.4 Roshen fringing not applicable to powder/distributed-gap core (MPP-60u). Use μ_e(H_dc) lookup via engine.dc_bias. Tier A returns analytical fringing = 0; relying on it for thermal calc may underestimate eddy loss by 50–100%.",
      "§13.10 Litz strand oversized: f_opt = 2529kHz vs design 100kHz; switching to thinner strands would not help — switch to solid AWG.",
      "⛔ §11.7 Lifetime 0.2y dominated by 'coffin_manson'. Below typical 5-year service requirement.",
      "§11.7 Thermal cycling dominates: ΔT=69.0°C/cycle. Reduce ΔT via better thermal management or pick more compliant potting."
    ],
    "citations": [
      "McLyman Ch.10 (Boost PFC)",
      "Self-study_Hoang.docx §2"
    ],
    "trust_score": 62.0,
    "trust_breakdown": {
      "energy_balance": 20.0,
      "mesh_convergence": 15.0,
      "reference_benchmark": 15.0,
      "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": 494.2,
        "uncertainty_pct": 10.0,
        "ci_low_2sigma": 395.36,
        "ci_high_2sigma": 593.04,
        "method": "engine→Lm_pct"
      },
      "Lk_uH": {
        "value": 0.0,
        "uncertainty_pct": 20.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 0.0,
        "method": "engine→Lk_pct"
      },
      "Pcv_W": {
        "value": 3.2,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 1.6,
        "ci_high_2sigma": 4.8,
        "method": "engine→Pcv_in_range_pct"
      },
      "Pcu_W": {
        "value": 1.431,
        "uncertainty_pct": 50.0,
        "ci_low_2sigma": 0.0,
        "ci_high_2sigma": 2.862,
        "method": "engine→Rac_near_gap_pct"
      },
      "Hotspot_C": {
        "value": 109.0,
        "uncertainty_pct": 4.59,
        "ci_low_2sigma": 99.0,
        "ci_high_2sigma": 119.0,
        "method": "engine→T_hotspot_C"
      },
      "PDIV_V": {
        "value": 540.0,
        "uncertainty_pct": 25.0,
        "ci_low_2sigma": 270.0,
        "ci_high_2sigma": 810.0,
        "method": "engine→PDIV_margin_pct"
      },
      "Cps_pF": {
        "value": 0.0,
        "uncertainty_pct": 2500.0,
        "ci_low_2sigma": -0.0,
        "ci_high_2sigma": 0.0,
        "method": "engine→EMI_Cps_pct"
      },
      "Lifetime_h": {
        "value": 2748857.0,
        "uncertainty_pct": 3.0,
        "ci_low_2sigma": 2583925.58,
        "ci_high_2sigma": 2913788.42,
        "method": "engine→lifetime_factor"
      }
    },
    "validity_warnings": [
      "⛔ §13.4 Roshen fringing not applicable to powder/distributed-gap core (MPP-60u). Use μ_e(H_dc) lookup via engine.dc_bias. Tier A returns analytical fringing = 0; relying on it for thermal calc may underestimate eddy loss by 50–100%.",
      "§13.10 Litz strand oversized: f_opt = 2529kHz vs design 100kHz; switching to thinner strands would not help — switch to solid AWG."
    ],
    "monte_carlo": {
      "Lm_uH": {
        "metric": "Lm_uH",
        "n_samples": 300,
        "mean": 262.3743,
        "stdev": 37.2384,
        "p5": 202.1729,
        "p50": 266.2334,
        "p95": 317.9182,
        "cpk_lower": -1.633,
        "cpk_upper": 2.518
      },
      "Pcv_W": {
        "metric": "Pcv_W",
        "n_samples": 300,
        "mean": 3.2128,
        "stdev": 0.2642,
        "p5": 2.7838,
        "p50": 3.1986,
        "p95": 3.6758,
        "cpk_lower": 1.026,
        "cpk_upper": 0.993
      },
      "eta": {
        "metric": "eta",
        "n_samples": 300,
        "mean": 0.9897,
        "stdev": 0.0005,
        "p5": 0.9888,
        "p50": 0.9897,
        "p95": 0.9905,
        "cpk_lower": 6.369,
        "cpk_upper": 6.38
      },
      "Hotspot_C": {
        "metric": "Hotspot_C",
        "n_samples": 300,
        "mean": 108.9449,
        "stdev": 2.9314,
        "p5": 104.3818,
        "p50": 108.9358,
        "p95": 113.4141,
        "cpk_lower": 1.233,
        "cpk_upper": 1.246
      },
      "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": 41.9851,
        "P_classical_eddy_W_per_m3": 0.0006,
        "P_excess_W_per_m3": 11.3137,
        "P_total_W_per_m3": 53.2995,
        "fraction_h": 0.7877,
        "fraction_c": 0.0,
        "fraction_a": 0.2123,
        "dominant_mechanism": "hysteresis-dominant (low-f regime)"
      },
      "acoustic": {
        "f_acoustic_hz": 200000.0,
        "in_audible_band": false,
        "spl_db_estimate": 49.0,
        "lambda_s_ppm": 5.0
      },
      "aging": {
        "L_total_h": 1726.0,
        "L_total_y": 0.2,
        "dominant": "coffin_manson",
        "L_thermal_h": 2795553.0,
        "L_eyring_h": 7846.0,
        "L_coffin_manson_h": 2215.0,
        "L_ipl_h": 128203042.0
      },
      "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
      },
      "reference_benchmark": {
        "ref_id": "erickson_maksimovic_pfc_500w",
        "passed": true,
        "checks": {
          "n_pri_range": {
            "value": 79,
            "min": 40,
            "max": 110,
            "passed": true
          },
          "lm_uh_range": {
            "value": 494.2,
            "min": 400,
            "max": 1200,
            "passed": true
          },
          "eta": {
            "value": 0.9897,
            "min": 0.96,
            "max": 0.995,
            "passed": true
          },
          "p_total_w": {
            "value": 5.195,
            "max": 11.0,
            "passed": true
          },
          "core_shape": {
            "value": "Toroid",
            "allowed": [
              "Toroid"
            ],
            "passed": true
          }
        },
        "source": "Erickson & Maksimović, Fundamentals of Power Electronics 3rd ed. Ch.18 PFC boost example"
      }
    },
    "window_breakdown": {
      "core_window_mm2": 169.71668912855458,
      "after_walls_mm2": 169.71668912855458,
      "after_margin_mm2": 169.71668912855458,
      "after_pin_leadout_mm2": 169.71668912855458,
      "deduction_pct": 0.0,
      "warning": "no bobbin spec; using core.aw_mm2 directly",
      "ku_target": 0.3,
      "ku_key": "litz_manual_served",
      "used_ku": 1.474,
      "a_winding_mm2": 250.22
    },
    "bobbin_pn": "",
    "material_score": {
      "loss": 0.0,
      "saturation": 87.6,
      "freq_fit": 100.0,
      "dc_bias": 75.0,
      "acoustic": 100.0,
      "app_match": 70.0,
      "cost": 82.3,
      "availability": 100.0,
      "ap_fit": 20.0,
      "thermal": 97.1,
      "total": 65.8,
      "rationale": [
        "Pcv≈29102 mW/cm³ at design point",
        "Bsat margin=38% at 109°C",
        "fsw/f_res=0.00 (f_res≈106667kHz)",
        "no DC bias requirement",
        "f_acoustic=200000Hz outside audible",
        "industrial — flexible material choice",
        "$2.77/qty1k",
        "6 cross-vendor equivalents — supply resilient",
        "Ap ratio 21.93 much oversized",
        "Ve=5710mm³ for 500W (ratio=1.43)"
      ]
    },
    "top_3_alternatives": [
      {
        "pn": "Micrometals_T130-Micrometals_26",
        "vendor": "Micrometals",
        "material": "Material -26",
        "shape": "Toroid",
        "ae_mm2": 73.2,
        "ve_mm3": 5710.0,
        "score_total": 65.8,
        "score_breakdown": {
          "loss": 0.0,
          "saturation": 87.6,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 82.3,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 97.1
        },
        "rationale": [
          "Pcv≈29102 mW/cm³ at design point",
          "Bsat margin=38% at 109°C",
          "fsw/f_res=0.00 (f_res≈106667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "industrial — flexible material choice",
          "$2.77/qty1k",
          "6 cross-vendor equivalents — supply resilient",
          "Ap ratio 21.93 much oversized",
          "Ve=5710mm³ for 500W (ratio=1.43)"
        ]
      },
      {
        "pn": "Micrometals_T106-Micrometals_26",
        "vendor": "Micrometals",
        "material": "Material -26",
        "shape": "Toroid",
        "ae_mm2": 65.4,
        "ve_mm3": 4280.0,
        "score_total": 64.3,
        "score_breakdown": {
          "loss": 0.0,
          "saturation": 87.6,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 88.5,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 82.8
        },
        "rationale": [
          "Pcv≈29102 mW/cm³ at design point",
          "Bsat margin=38% at 109°C",
          "fsw/f_res=0.00 (f_res≈106667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "industrial — flexible material choice",
          "$2.15/qty1k",
          "6 cross-vendor equivalents — supply resilient",
          "Ap ratio 10.51 much oversized",
          "Ve=4280mm³ for 500W (ratio=1.07)"
        ]
      },
      {
        "pn": "Micrometals_T200-Micrometals_52",
        "vendor": "Micrometals",
        "material": "Material -52",
        "shape": "Toroid",
        "ae_mm2": 121.0,
        "ve_mm3": 13700.0,
        "score_total": 63.7,
        "score_breakdown": {
          "loss": 0.0,
          "saturation": 87.6,
          "freq_fit": 100.0,
          "dc_bias": 75.0,
          "acoustic": 100.0,
          "app_match": 70.0,
          "cost": 56.3,
          "availability": 100.0,
          "ap_fit": 20.0,
          "thermal": 100.0
        },
        "rationale": [
          "Pcv≈36862 mW/cm³ at design point",
          "Bsat margin=38% at 109°C",
          "fsw/f_res=0.00 (f_res≈106667kHz)",
          "no DC bias requirement",
          "f_acoustic=200000Hz outside audible",
          "industrial — flexible material choice",
          "$6.22/qty1k",
          "6 cross-vendor equivalents — supply resilient",
          "Ap ratio 93.49 much oversized",
          "Ve=13700mm³ for 500W (ratio=3.42)"
        ]
      }
    ]
  },
  "kpi": {
    "eta_pct": 98.97,
    "trust_grade": "B",
    "trust_score": 62.0,
    "core_pn": "Magnetics_55121-Magnetics_MPP_60u",
    "bobbin_pn": "",
    "n_pri": 79,
    "n_sec": 0,
    "air_gap_mm": 1.614,
    "p_total_w": 5.2,
    "hotspot_c": 109.0,
    "b_peak_t": 0.8
  },
  "screenshot_path": "/marketing/gallery/pfc-500w.png",
  "deep_link": "/calculator?gallery=pfc-500w",
  "engine_version": "v1.8.0+day3_audit",
  "generated_at": "2026-05-23T05:10:14Z"
}