The edges that are lengths
Assumes: Every model has an edge · Kirchhoff's own frequency
Every model has an edge put four of this collection’s boundaries on one axis, and the axis was frequency. The edge that is a region added a second dimension and found boundaries that bound from both sides. The edges that move with the room added a third variable, temperature, and found that every boundary already computed had a temperature hidden in it.
All of those are quantities a circuit designer sets. A frequency is on the specification. An amplitude is a signal level. A temperature is an ambient with a number beside it.
There is a fourth kind, and it has turned up four times in this field without ever being collected: a boundary that is a distance. Not a distance in a formula — every physical constant has lengths in it — but a boundary whose independent variable is a millimetre, and which therefore cannot be read off a circuit diagram, cannot be simulated from a netlist, and does not move when the frequency does.
The four that are lengths
The reach of a fringing field: 0.60 millimetres. A gap in a core throws a field into the winding window, and the excess loss it causes falls off exponentially with the clearance between the gap and the copper. Fitted, the decay length is 0.60 mm — and the useful part is that it stays near 0.60 when the gap itself changes by a factor of five, so it belongs to the core’s geometry rather than to the gap.
The height of a track above its plane: 200 microns. The return current under a track spreads sideways over a distance set by that height, so the loop the pair encloses — and therefore the inductance, and therefore what it radiates — is a function of a dimension in the stack-up rather than of anything in the schematic.
The size of the circuit: ten centimetres. Kirchhoff’s laws are a statement about a circuit small compared with a wavelength, and the frequency at which they fail is proportional to one over the size.
And the packing of a winding: a ratio of lengths. The porosity factor and the window fill are both dimensionless, which makes them look like different objects from the three above; they are not, since both are one length divided by another and both are set on the winding machine.
A fifth, which is a length that is a time
There is one more in the collection and it belongs in the list with a qualification, because it is a length that has been converted into something else before anybody sees it.
A transmission line’s delay is its length divided by a velocity, and every reflection argument in the lines field is written in nanoseconds rather than in centimetres — the staircase in time counts round trips, and a round trip is twice a length. The conversion is exact and it hides the provenance: a delay is a number a designer can put on a timing budget, and the centimetres it came from are on a drawing somebody else owns.
The same conversion happens to every one of the four above, sooner or later. A clearance becomes a watt. A window fill becomes an alternating-current resistance. A track height becomes an inductance. And once converted, the number joins the electrical model and stops being visibly a length at all — which is exactly how a boundary set by a dimension ends up being verified by a simulation that has no dimensions in it.
What they have in common
Three things, and the third is the one worth the essay.
They do not move with frequency. A reach of 0.60 mm is 0.60 mm at ten kilohertz and at one megahertz, unlike every boundary how small is small signal and its neighbours compute. The consequence of standing inside it moves with frequency — the excess loss goes as the square of a field that goes with the current — but the boundary itself is a property of a geometry and a permeability, both of which are constants. That is unusual in this collection: almost every other edge here is a frequency, and a frequency moves when anything moves.
They are set by manufacture rather than by design. A designer chooses a switching frequency, a turns count, a wire gauge and a core. A designer does not choose how much former is under the first layer, or whether the winder pulled the tape tight, or which of two identical-looking bobbins the line was using that week. Every one of those is a length, and the four boundaries above are functions of exactly that kind of length. The nearest thing in the rest of the collection is the tolerance that is not on any part, where a response’s spread comes from an interaction no single component’s specification contains.
And they are absent from every electrical representation of the circuit. This is the important one. A schematic has no lengths in it. A netlist has no lengths in it. A simulation of a converter has an inductance, a resistance and a core loss model, and every one of those is a number that was computed somewhere else from a geometry the simulation cannot see. So a length-shaped boundary survives every electrical review that a design gets, and shows up in the first thermal measurement of the first build — which is exactly where it is most expensive to find.
The one that is a length and a frequency at once
Two of the four are not purely lengths, and the way they are not is instructive.
Kirchhoff’s boundary is a length and a frequency: a ten-centimetre circuit is lumped below 3.97 megahertz and a one-centimetre circuit below 39.7. So the boundary is really a product — a size times a frequency — and the size is one factor of it.
The skin depth is the same shape. A conductor’s resistance departs from its direct-current value where the skin depth is comparable with the radius, and the skin depth is √(2ρ/ωµ): another length, this time one the material sets rather than the manufacturer.
That distinction — a length somebody chose against a length physics computed — is what separates the two halves of this list. A skin depth and a wavelength are properties of a material and a frequency, and they can be worked out at the desk. A gap clearance and a window fill are properties of an object that has been built, and they cannot.
Why the collection kept finding them here
Three of the four are in the magnetics field and that is not an accident.
A magnetic component is the one part in an ordinary circuit whose internal geometry is the design. A resistor is a value; a capacitor is a value and two parasitics; a transistor is a model card. A transformer is a window with copper arranged in it, and every parameter it has — the magnetising inductance, the leakage inductance, the alternating-current resistance, the interwinding capacitance, the fringing loss — is a statement about where things are relative to each other.
So a magnetic part is where a length-shaped boundary is most likely to be found, and it is also where it is hardest to see, because the part arrives with a data sheet that has numbers on it and no drawing — the same gap between a value and an object that the assumption that is a geometry measures inside a winding.
Why the collection did not notice sooner
The honest answer is that it had not built anything whose geometry it could solve.
Every boundary in the first three rungs of this ladder came out of a lumped model: a netlist, a transfer function, a marched circuit. A lumped model is one in which the geometry has already been reduced to element values, and a boundary computed from element values is necessarily a frequency, an amplitude or a temperature — because those are the only variables left.
Adding a field changed what could be asked. The three magnetic boundaries above all came from solving a cross-section rather than a netlist, and the first thing a cross-section has that a netlist does not is a coordinate. So this rung is less an observation about electronics than about what a model is capable of noticing: a boundary can only be expressed in the variables the model has, and a lumped model has no lengths.
That is also the warning to attach to it. There are certainly length-shaped boundaries in the fields this collection has not solved a field for, and they will stay invisible for the same reason — not because nobody looked, but because the representation being looked at cannot hold one.
What to do about a boundary nobody can see
The three responses are not equivalent and they are worth ranking.
Turn it into an electrical number and put it on the drawing. A clearance from the gap becomes a minimum first-layer former thickness with a tolerance; a window fill becomes a stated margin; a track height becomes a stack-up requirement. This works and it is what a mature design does, and its weakness is that it moves the problem into a document rather than removing it.
Design so the boundary does not bind. Split the gap so there is no concentrated fringing field; interleave so the leakage does not depend on a single insulation thickness; use a plane so the return path has no choice about where to go. This is better and it costs area, turns or layers.
Or measure the built object. A length-shaped boundary is invisible to simulation and obvious in a thermal image, which is why the first article of a magnetic part gets a thermal survey and the first article of an amplifier does not — and why the degrees a thermocouple cannot see is worth knowing before reading one.
The three questions to ask of a length-shaped limit
A frequency limit gets three standard questions: where is it, how sharp is it, and what happens past it. A length limit needs different ones, and the collection’s four suggest what they are.
Who controls it? A skin depth is controlled by physics and a frequency; a gap clearance is controlled by a winder. The first can be designed against and the second can only be specified and inspected. This question is the one that decides whether the limit belongs in an analysis or in a drawing note.
What does it scale with? The reach of a fringing field turned out to scale with the leg rather than with the gap, which is why the trade rule stated in gap lengths is wrong in both directions. Getting the scaling right is usually more valuable than getting the coefficient right, because a coefficient is one design and a scaling is all of them.
And how much variation is there? A reach of 0.60 millimetres means half a millimetre of winding variation is a factor of two in the excess loss. A boundary whose variable has a manufacturing tolerance comparable with the boundary itself is not a limit, it is a distribution — which is the same shape of statement the tolerance that is not on any part makes about component spreads, arriving from a dimension rather than from a value.
What this rung does not claim
It is not a new mechanism. Every boundary listed was measured in its own essay with its own machinery; this rung is a statement about what they have in common, and the only thing it adds is the observation that four of them share a kind of variable.
And “length” is doing some work. A window fill is dimensionless, a porosity is dimensionless, and a clearance is in millimetres. What they share is not the unit but the provenance: each is a measurement of the built object rather than a value assigned to a component, and each is therefore absent from the representation the design was verified in.
That is the honest form of the claim, and it is narrower than “there are boundaries that are lengths”. There are boundaries whose variable is a fact about the physical arrangement, and no schematic contains one.
The number worth carrying
There is no single number here, which is itself the point. What is worth carrying is the question: which of this design’s limits are set by things the drawing does not contain?
For a magnetic component the answer is most of them. For a circuit board it is the stack-up and the return path. For a discrete amplifier it is very nearly none, which is why the habit of asking does not develop until somebody has built a transformer.
Two more that were not on the list
Two boundaries elsewhere in the collection belong on this axis and are easy to miss, because in both cases the length is inside a package rather than on a board.
The current that does not reach the input is one: a teraohm across a board from a fifteen-volt rail is fourteen millivolts of error through a gigohm source, a humid morning takes that resistance down two decades, and the whole of the effect is in a resistance nobody drew, between two features whose spacing was chosen by a layout tool. A guard ring takes the same error to a nanovolt, and the design parameter is a clearance.
The resistance that is below zero is the other and it is the sharpest, because the length is not even a design feature. An emitter follower’s output resistance is 5.5 Ω at direct current and −21.9 Ω at 257 MHz, and the sign does not belong to the transistor: with an ideal source at the base there is no negative band at all, and a hundred nanohenries of wire between the source and the base produces one from 110 to 301 MHz. Seven centimetres of lead, which is a length nobody specified, decides whether a circuit oscillates — and the input that pushes back finds the threshold at 74.9 nanohenries with ten ohms of source, rising to 913 with a hundred, so the repair is the opposite of the instinct.
Which extends this essay’s question by one clause. It is not only which of a design’s limits are set by things the drawing does not contain, but also which of them are set by things that vary between one build and the next without anybody having decided to change them. A gap length is chosen once by whoever makes the core; a lead length is chosen implicitly, differently, by whoever assembles each unit.
That second class is the one with no design remedy, and the honest response to it is the one the input that pushes back arrives at: make the circuit insensitive to the length rather than trying to control the length. Ten ohms of source resistance puts the oscillation threshold at 74.9 nanohenries, which is seven centimetres of wire and is inside what an assembly will produce; a hundred ohms puts it at 913, which is most of a metre and is not. The fix for a follower that oscillates is to make the thing driving it worse, and that is a schematic change against a boundary that is not on the schematic.
The general form of that remedy is worth stating because it is the only one available for this whole class. A length cannot be specified into a netlist, and a design that depends on one is a design whose behaviour is decided by whoever builds it. What can be done is to move the threshold far enough that every length an assembly plausibly produces is on the safe side of it — which is not a smaller sensitivity but a larger margin, and which is why the numbers in this essay are worth having as numbers rather than as cautions. A margin cannot be sized against a warning.
Part 4 on model edges
One argument about Model edges, and one of 5 essays on it so far, each part numbered by how much of the idea it assumes. What sits either side of it:
What links here
Essays that reach for this one mid-argument — the half of a link its own author cannot write down, the 8 sharing most with it of 21.
The objects named here
The third axis, after the field and the idea: the things themselves, and every essay that touches each one.
Design tradeoffFringing fieldLumped-elementMeasurement conditionModel rangeModel refusalParasiticsProximity effectReturn current
- Interleaving is a choice, not an improvement design tradeoff, measurement condition, model range, return current
- The optimum a spectrum moves design tradeoff, measurement condition, model range, proximity effect
- The resistor that is right in size and wrong in angle lumped-element, measurement condition, model range, parasitics
- The width no load can change design tradeoff, measurement condition, model range, parasitics
- A band rather than an edge design tradeoff, model range, parasitics
- The band that does not close design tradeoff, model range, parasitics