AI Flow
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Adom's AI Flow: a tool to help the AI follow all of the steps it takes to build a board.
Independent coupled ESC thermal solve exceeds budget despite heuristic pass
The 0.1.15 thermal heuristic passes Astra's delivered ESC (worst reported rise approximately 53 C), but an independent coupled four-layer conduction solve exceeds the same 60 C hot-tab rise budget under the explicitly stated air assumptions. The original delivered qualification is a historical heuristic result; this post-delivery analysis must not be presented as an independent thermal pass.
Own source code parses native filled polygons, tracks, all pad geometries and drill holes, and every via/PTH barrel. It reproduces KiCad's native filled-zone areas. DC uses each spec load, explicit terminal boundary conditions, layer sheet conductance and plated barrels; every solved source/sink is connected. An analytic strip and 5:1 constriction fixture pass, and electrical source/Joule power balances close. DC loss changes from 2.32003 to 2.32715 W between 0.2 and 0.1 mm meshes.
Thermal uses the actual 35/15.2/15.2/35 micrometre copper and 0.2104/1.065/0.2104 mm dielectric stack. Each layer spreads in plane; dielectric and all 473 plated barrels couple layers; both outer faces convect. The inputs are the specified 4.1 W at seven hot tabs plus calculated copper Joule heat. Copper conductivity 400 W/mK, FR4 0.3 W/mK, barrel plating 25 micrometres, and air coefficients 10 and 25 W/m2K are stated assumptions. No radiation, chassis, heatsink, package junction model, or cable cooling. Independent phase stress cases are combined conservatively for heating; this is not a switching-cycle simulation or measured qualification.
Each chip's own heat split is obtained by a separate linear response and flux through a 4 mm control region, so neighboring-chip heat is not falsely credited to its vias. Along-copper, via, dielectric, FR4 and local-air paths balance the full injected watts. The code and numerical reports are attached for reuse in the binary. The useful repair is coupled board-wide spreading and summed loss, instead of treating every hot tab as independently using the net's entire copper area.
Refinement results (coarse 0.2 mm; fine 0.1 mm used in drawings):
{
"still": {
"coarsePeakRiseC": 117.76504156092778,
"finePeakRiseC": 122.45739298979633,
"peakChangeC": 4.692351428868548,
"energyErrorW": -3.1186253579562617e-10
},
"moving": {
"coarsePeakRiseC": 67.58259208291467,
"finePeakRiseC": 70.70510939002497,
"peakChangeC": 3.1225173071103,
"energyErrorW": -7.390710266008682e-11
}
}
The peaks and local heat splits remain mesh-sensitive; no claim of mesh-converged temperature or package thermal fractions is made. The 60 C failure is unchanged on refinement.
