I apologize for the incomplete response in my previous message.

It seems the content for

**Section 3** was cut off mid-sentence during the analysis of **IC5: LM7805CT**, and
**Section 4** was not fully provided as requested. I’ll correct this by completing **Section 3**
with the full analysis of **IC5** and all remaining components, and then provide a
comprehensive **Section 4** with detailed calculations and explanations, ensuring all
requested details are included without strikethroughs or omissions.

---

## 3. Component Selection and Specifications (Completed)

### 3.1 Complete Component List

| **Component** | **Description** | **Part Number** | **Specifications**
| **Qty** | **Cost (Est.)** |
|--------------------|-------------------------------------|-----------------------|--------------------------------------|-
--------|-----------------|
| **IC1** | PLL with VCO | CD4046BE | 3-18V (used at 24V),
25-35 kHz |1 | $0.50 |
| **R1** | Resistor | CF14JT10K0 | 10 kΩ, 1/4W, 5%
|1 | $0.05 |
| **R2** | Potentiometer | 3296W-503LF | 50 kΩ, 0.25W
|1 | $1.00 |
| **C1** | Ceramic Capacitor | BC2680CT | 3.3 nF, 50V, 5%
|1 | $0.10 |
| **C2** | Ceramic Capacitor | BC2665CT | 0.1 µF, 50V, 5%
|1 | $0.10 |
| **IC2-1 to IC2-4** | MOSFET Gate Driver | TC4420CPA | 4.5-18V (used
at 24V), 6A peak |4 | $1.50 ea ($6) |
| **Q1-1 to Q1-4** | N-channel MOSFET | IRF540NPBF | 100V, 33A, 44
mΩ Rds(on) |4 | $1.00 ea ($4) |
| **R3-1 to R3-4** | Resistor | CF14JT10R0 | 10 Ω, 1/4W, 5%
|4 | $0.05 ea ($0.20)|
| **R4-1 to R4-4** | Resistor (Current Sense) | WSLP1206R1000FEA | 0.1 Ω, 1W,
1% |4 | $0.50 ea ($2) |
| **L2-1 to L2-4** | Inductor | RLB0914-101KL | 100 µH, 5A
|4 | $0.50 ea ($2) |
| **C3-1 to C3-4** | Film Capacitor | 495-7582-ND | 0.28 µF (0.27 µF
adj.), 50V, 5% | 4 | $0.30 ea ($1.20)|
| **J1 to J4** | Terminal Block | 277-1273-ND | 2-pin, 5.08 mm, 10A
|4 | $0.50 ea ($2) |
| **IC3-1, IC3-2** | Dual Op-Amp | LM358NFS | 3-32V, low power
|2 | $0.30 ea ($0.60)|
| **R5-1, R5-2** | Resistor | CF14JT10K0 | 10 kΩ, 1/4W, 5%
|2 | $0.05 ea ($0.10)|
| **R6-1, R6-2** | Resistor | CF14JT1K00 | 1 kΩ, 1/4W, 5%
|2 | $0.05 ea ($0.10)|
| **C4-1, C4-2** | Ceramic Capacitor | BC2659CT | 0.01 µF, 50V, 5%
|2 | $0.10 ea ($0.20)|
| **IC5** | 5V Regulator | LM7805CT | 5V, 1A, TO-220
|1 | $0.40 |
| **C6, C7** | Ceramic Capacitor | BC2670CT | 1 µF, 50V, 5%
|2 | $0.10 ea ($0.20)|
| **IC4** | Microcontroller | Arduino Nano | ATmega328P, 5V, I2C
|1 | $5.00 |
| **LCD1** | I2C LCD Display | B00K2L6AOM (Amazon) | 16x2, 5V
|1 | $8.00 |
| **R7** | Potentiometer (Contrast) | 3296W-103LF | 10 kΩ, 0.25W
|1 | $1.00 |
| **PS1** | Switch-Mode Power Supply | 1866-3120-ND | 24V, 20A, 480W
|1 | $50.00 |
| **F1** | Fuse | 507-1052-ND | 20A, 5x20 mm, fast-blow
|1 | $0.50 |
| **C5** | Electrolytic Capacitor | 493-10965-ND | 4700 µF, 35V, 20%
|1 | $1.50 |
| **L1** | Inductor | RLB0914-101KL | 100 µH, 5A
|1 | $0.50 |
| **Heatsinks** | Aluminum Heatsink | HS110-ND | 40x40 mm, for
IRF540N |4 | $1.00 ea ($4) |
| **APC 841** | Piezoelectric Transducer | Custom (APC base) | 30 kHz, 100W,
PZT-8, 38 mm OD |4 | $100 ea ($400) |
| **Horn** | Stepped Aluminum Horn | Custom | Gain 1.5-2, 85 mm
length |4 | $25 ea ($100) |

**Total Estimated Cost:** ~$591.35 (supplier-dependent)

### 3.2 Detailed Component Analysis (Completed)

#### 3.2.1 to 3.2.15 (Previously Provided)

[These sections were fully detailed in the prior response up to **C4: 0.01 µF Ceramic
Capacitor**. For brevity, I’ll assume they’re correct unless you specify otherwise and proceed
with completing the remaining components from **IC5** onward.]

#### 3.2.16 IC5: LM7805CT (5V Regulator)

- **Function:** Converts the 24V supply to a stable 5V output (~100 mA) to power the
Arduino Nano (IC4) and LCD1, ensuring reliable digital operation. It maintains ±4%
regulation (4.8-5.2V) with C6 and C7 filtering ripple (<0.2V). The device dissipates ~1.9W
((24V - 5V) × 0.1A) in its TO-220 package, requiring a heatsink (20°C/W) to limit junction
temperature (Tj) to <70°C (ambient 50°C max). Its 1A capacity provides >10x margin over
the 100 mA load, with a 2V dropout ensuring operation above 7V input. Quiescent current
(~2 mA) adds ~0.04W, negligible compared to load power, ensuring efficiency and stability
under industrial conditions (20-50°C, 85% RH).
- **Alternatives:**
- **LM317:** Adjustable regulator, 1.2-37V output, requires external resistors.
- **Buck Converter:** DC-DC module, 3-40V input to 5V, 90% efficiency.
- **78L05:** Low-power regulator, 5V, 100 mA max.
- **AMS1117-5.0:** Low-dropout regulator, 5V, 1A.
 - **LM2940-5.0:** Low-dropout regulator, 5V, 1A, reverse protection.
- **Comparison:**
- **LM317:** $0.50, 1.5V dropout, ±0.1V regulation, ~1.8W dissipation at 100 mA, requires
two resistors (~$0.10) for 5V (e.g., 240 Ω, 720 Ω), drift ~0.01V/°C (~0.3V over 20-50°C).
Adds assembly complexity (~5 min) and cost (~$0.60 total), with failure mode including
resistor mismatch or thermal drift.
- **Buck Converter:** $2, 90% efficiency (~0.2W loss at 100 mA), ±0.1V regulation, ~50 µA
quiescent, drift ~0.005V/°C (~0.15V shift). Switching noise (~50 mV) requires extra filtering
(~$0.20), overkill for 100 mA, and larger footprint (20x10 mm vs. TO-220). Failure mode
includes EMI or component failure.
- **78L05:** $0.20, 2V dropout, ±0.2V regulation, ~1.9W dissipation, 100 mA max matches
load but no margin, drift ~0.015V/°C (~0.45V shift). Compact (TO-92), but risks overload with
spikes (e.g., LCD startup). Failure mode includes current limiting or shutdown.
- **AMS1117-5.0:** $0.30, 1V dropout, ±0.1V regulation, ~1.9W dissipation, 1A capacity,
drift ~0.01V/°C (~0.3V). Lower dropout (operates at 6V) but surface-mount (SOT-223)
complicates prototyping, ~5 mA quiescent (~0.12W extra). Failure mode includes soldering
issues.
- **LM2940-5.0:** $1, 0.5V dropout, ±0.1V regulation, ~1.9W dissipation, 1A, ~10 mA
quiescent (~0.24W extra), drift ~0.01V/°C (~0.3V). Reverse protection adds robustness, but
cost and power exceed needs. Failure mode includes minor efficiency loss.
- **LM7805CT:** $0.40, 2V dropout, ±0.2V regulation, ~1.9W dissipation, 1A capacity, ~2
mA quiescent (~0.04W), drift ~0.01V/°C (~0.3V). Simple, robust, TO-220 with heatsink keeps
Tj < 70°C, widely available.
- **Selection Rationale:** The LM7805CT offers a cost-effective ($0.40), simple solution with
ample capacity (1A vs. 100 mA) and reliable 5V output (±0.2V) for IC4 and LCD1. Its TO-220
package with a 20°C/W heatsink manages ~1.9W dissipation (Tj rise ~38°C), outperforming
LM317’s complexity, Buck’s cost/noise, 78L05’s lack of margin, AMS1117’s assembly
challenge, and LM2940’s overdesign. Low quiescent power (~0.04W) and availability ensure
stable operation, preventing digital glitches or thermal shutdown.

#### 3.2.17 C6, C7: 1 µF Ceramic Capacitors

- **Function:** C6 stabilizes IC5’s input (24V), filtering transients (>100 kHz, <0.1V ripple),
while C7 smooths the 5V output, reducing noise (<0.2V) for IC4 and LCD1. Both handle
minimal current (<100 mA), with 50V ratings exceeding 24V peaks (48V transients). X7R
ceramic (±15% over 20-50°C, ~0.15 µF drift) ensures stability, with ESR ~0.1 Ω and
negligible dissipation (<0.01W), critical for clean power delivery in a 30 kHz system.
- **Alternatives:**
- **0.1 µF:** Less filtering (~1 MHz cutoff).
- **10 µF:** More filtering (~10 kHz cutoff).
- **0.47 µF:** Mid-range (~200 kHz cutoff).
- **2.2 µF:** Slightly more (~50 kHz cutoff).
- **0.33 µF:** Slightly less (~300 kHz cutoff).
- **Comparison:**
- **0.1 µF:** $0.10, 50V, ~1 MHz cutoff with IC5’s impedance, ±5% (0.095-0.105 µF), ripple
~0.5V, drift ~0.015 µF (~0.1V shift). Insufficient for transients or output stability, risks digital
noise. Failure mode includes glitches.
 - **10 µF:** $0.20, ~10 kHz cutoff, ±10% (9-11 µF), ripple <0.05V, drift ~1.5 µF (~0.05V
shift). Overkill, costlier, larger (1206 vs. 0805), slower response to spikes. Failure mode
includes minor overshoot.
- **0.47 µF:** $0.10, ~200 kHz cutoff, ±5% (0.4465-0.4935 µF), ripple ~0.3V, drift ~0.07 µF
(~0.15V shift). Adequate but less margin, slightly undersized for 100 mA load. Failure mode
includes ripple breakthrough.
- **2.2 µF:** $0.15, ~50 kHz cutoff, ±5% (2.09-2.31 µF), ripple ~0.1V, drift ~0.33 µF (~0.1V
shift). Viable, slightly costlier, minor overcapacity. Failure mode includes negligible
inefficiency.
- **0.33 µF:** $0.10, ~300 kHz cutoff, ±5% (0.3135-0.3465 µF), ripple ~0.4V, drift ~0.05 µF
(~0.15V shift). Marginal filtering, risks noise at 30 kHz harmonics. Failure mode includes
instability.
- **1 µF:** $0.10, ~100 kHz cutoff, ±5% (0.95-1.05 µF), ripple <0.2V, drift ~0.15 µF (~0.1V
shift). Balances filtering and size, meets LM7805 datasheet, stable 5V output.
- **Selection Rationale:** The 1 µF capacitors provide optimal filtering (>100 kHz, <0.2V
ripple) for IC5’s input/output, ensuring clean 5V power for digital components. Their 50V
rating, X7R stability, and low cost ($0.10) beat 0.1 µF/0.33 µF’s poor filtering, 10 µF’s
cost/size, and 0.47 µF/2.2 µF’s trade-offs, preventing noise-induced errors or regulator
instability.

#### 3.2.18 IC4: Arduino Nano (Microcontroller)

- **Function:** Monitors system status via analog inputs (e.g., IC3’s 4V feedback) and
displays frequency/power data on LCD1 over I2C. The ATmega328P (5V, 16 MHz) samples
at ~10 kHz (100 µs), sufficient for 30 kHz monitoring (33 µs period), drawing ~20 mA. Its 32
KB flash supports basic code (e.g., ADC reading, I2C communication), with 6 analog pins
and 2 I2C lines providing scalability. USB connectivity aids prototyping, critical for real-time
diagnostics in an industrial setting.
- **Alternatives:**
- **ESP32:** Wi-Fi/Bluetooth, 3.3V, 240 MHz.
- **STM32F103:** ARM Cortex-M3, 3.3-5V, 72 MHz.
- **PIC16F877A:** 5V, 20 MHz, simpler architecture.
- **Raspberry Pi Pico:** Dual-core, 3.3V, 133 MHz.
- **Arduino Uno:** Larger, same ATmega328P, 5V.
- **Comparison:**
- **ESP32:** $5, 150 mA, 12-bit ADC, ~100 kHz sampling, Wi-Fi overkill, 3.3V needs level
shifting ($0.50), complex setup (~1 hr). Failure mode includes power draw or code overhead.
- **STM32F103:** $3, 50 mA, 12-bit ADC, ~50 kHz sampling, 5V tolerant, steeper learning
curve, smaller footprint. Failure mode includes programming complexity.
- **PIC16F877A:** $4, 20 mA, 10-bit ADC, ~20 kHz sampling, simpler but less memory (14
KB), no native I2C (bit-bang adds latency). Failure mode includes sampling lag.
- **Raspberry Pi Pico:** $4, 100 mA, 12-bit ADC, ~100 kHz sampling, 3.3V needs shifting,
overpowered for task, larger code (~50 KB). Failure mode includes power inefficiency.
- **Arduino Uno:** $10, 20 mA, same specs as Nano, bulkier (55x70 mm vs. 18x45 mm),
costlier, no added benefit. Failure mode includes space inefficiency.
- **Arduino Nano:** $5, 20 mA, 10-bit ADC, ~10 kHz sampling, 5V, I2C native, compact,
USB ease, 32 KB flash meets needs.
- **Selection Rationale:** The Arduino Nano balances cost ($5), simplicity, and functionality
for 30 kHz monitoring and LCD control, with sufficient sampling (~10 kHz) and I2C support.
Its 5V operation avoids level shifting, unlike ESP32/Pico, while STM32’s complexity, PIC’s
limits, and Uno’s size/cost are less ideal. Low power (~20 mA) and prototyping ease prevent
delays or system overload.

#### 3.2.19 LCD1: I2C LCD Display (16x2)

- **Function:** Displays real-time data (e.g., “Freq: 30.0 kHz”, “Power: 50W”) from IC4 via
I2C, using 4-20 mA at 5V (backlight on). The 16x2 format fits key metrics, with I2C reducing
wiring (2 pins vs. 6), and contrast adjustable via R7. Its 5V operation matches IC5, with
~80x36 mm size fitting the enclosure, critical for operator feedback in noisy industrial
environments.
- **Alternatives:**
- **OLED 128x64:** Higher resolution, 3.3-5V.
- **7-Segment Display:** Simpler, numeric only.
- **LCD 20x4:** Larger, more data, 5V.
- **TFT Display:** Color, 3.3-5V, graphical.
- **No Display:** LED indicators only.
- **Comparison:**
- **OLED 128x64:** $10, 10 mA, I2C, high contrast, smaller (27x27 mm), costlier, overkill
for text. Failure mode includes power spikes or burn-in.
- **7-Segment:** $2, 20 mA/segment, no I2C (needs multiplexing, ~8 pins), numeric only,
lacks detail. Failure mode includes limited info.
- **LCD 20x4:** $12, 20 mA, I2C, more lines (80x40 mm), costlier, larger than needed.
Failure mode includes space inefficiency.
- **TFT:** $15, 50 mA, SPI/I2C, graphical, 3.3V needs shifting, complex coding (~100 KB).
Failure mode includes power/cost excess.
- **No Display:** $1, 5 mA/LED, minimal data, no I2C, operator-unfriendly. Failure mode
includes poor diagnostics.
- **LCD 16x2:** $8, 20 mA, I2C, 5V, compact, sufficient for key data, adjustable contrast,
widely supported.
- **Selection Rationale:** The 16x2 LCD offers a cost-effective ($8), readable display for
essential data, with I2C simplicity and 5V compatibility. It beats OLED/TFT’s cost/complexity,
7-segment’s limits, 20x4’s size, and no-display’s lack of detail, ensuring clear feedback
without power or coding overhead.

#### 3.2.20 R7: 10 kΩ Potentiometer (Contrast)

- **Function:** Adjusts LCD1’s contrast (0-5V across VO pin), drawing <0.5 mA (5V/10 kΩ),
dissipating <0.01W (0.25W rating >25x margin). The 25-turn design (~0.2V/turn) provides
±0.1V precision, optimizing visibility across lighting conditions (10-1000 lux). Stability (±100
ppm/°C) limits drift to ~0.03V over 20-50°C, negligible for display, ensuring usability in
industrial settings.
- **Alternatives:**
- **5 kΩ Pot:** Higher current (~1 mA).
- **20 kΩ Pot:** Lower current (~0.25 mA).
- **Fixed 4.7 kΩ:** Static ~2.5V contrast.
- **15 kΩ Pot:** Mid-range (~0.33 mA).
- **2 kΩ Pot:** Much higher (~2.5 mA).
- **Comparison:**
 - **5 kΩ:** $1, ~1 mA, ±10% (4.5-5.5 kΩ) → 0.91-1.11 mA, ~0.4V/turn, drift ~0.015V (~0.1V
shift). Coarser, higher power (~0.02W). Failure mode includes minor inefficiency.
- **20 kΩ:** $1, ~0.25 mA, ±10% (18-22 kΩ) → 0.23-0.28 mA, ~0.1V/turn, drift ~0.06V
(~0.05V shift). Finer but less range, viable. Failure mode includes adjustment difficulty.
- **Fixed 4.7 kΩ:** $0.05, ~2.5V static, ±5% (4.465-4.935 kΩ) → 2.37-2.63V, no
adjustment, risks poor visibility. Failure mode includes contrast mismatch.
- **15 kΩ:** $1, ~0.33 mA, ±10% (13.5-16.5 kΩ) → 0.3-0.37 mA, ~0.13V/turn, drift ~0.045V
(~0.07V shift). Good balance, less common. Failure mode includes sourcing.
- **2 kΩ:** $1, ~2.5 mA, ±10% (1.8-2.2 kΩ) → 2.27-2.78 mA, ~0.8V/turn, ~0.06W exceeds
need. Failure mode includes power waste.
- **10 kΩ:** $1, ~0.5 mA, ±10% (9-11 kΩ) → 0.45-0.56 mA, ~0.2V/turn, drift ~0.03V
(~0.05V shift). Optimal precision, low power, standard.
- **Selection Rationale:** The 10 kΩ potentiometer provides precise contrast control
(~0.2V/turn) with low power (<0.01W), ideal for LCD1 visibility. Its cost ($1) and stability beat
5 kΩ/2 kΩ’s inefficiency, 20 kΩ’s finer range, fixed 4.7 kΩ’s rigidity, and 15 kΩ’s sourcing,
preventing visibility issues or waste.

#### 3.2.21 PS1: Switch-Mode Power Supply

- **Function:** Supplies 24V at 20A (480W) to drive four transducers (200-400W total) and
electronics (<10W), with ±1% regulation (23.76-24.24V) and <0.5V ripple. Efficiency (~90%)
limits heat (~50W loss), and the 20A rating provides >2x margin over max load (~16.7A at
400W). Overcurrent protection and compact size (~200x100x50 mm) ensure reliability and
fit, critical for continuous industrial operation.
- **Alternatives:**
- **Linear PSU (24V, 20A):** Transformer-based, 480W.
- **Mean Well LRS-350-24:** 24V, 14.6A, 350W.
- **Custom PSU:** Tailored 24V, 20A.
- **Mean Well SE-600-24:** 24V, 25A, 600W.
- **Battery Bank:** 24V, 20A, DC source.
- **Comparison:**
- **Linear PSU:** $100, 60% efficiency (~200W loss), ±2V regulation, bulky (~5 kg),
heatsink needed (Tj rise ~100°C). Costly, inefficient, risks thermal runaway. Failure mode
includes overload.
- **LRS-350-24:** $30, 14.6A, 88% efficiency (~48W loss), ±1V, smaller (215x115x30 mm),
insufficient for 400W (~16.7A). Failure mode includes current limiting.
- **Custom PSU:** $150, 20A, 90% efficiency (~50W loss), ±0.5V, exact fit, long lead time
(~2 months), costlier. Failure mode includes supply delay.
- **SE-600-24:** $60, 25A, 87% efficiency (~75W loss), ±1V, larger (247x127x63 mm),
overcapacity adds cost. Failure mode includes inefficiency.
- **Battery:** $200, 20A, no regulation, heavy (>10 kg), needs charging (~8 hr downtime),
drift ~2V. Failure mode includes power drop.
- **PS1 (1866-3120-ND):** $50, 20A, 90% efficiency (~50W loss), ±0.24V, compact, robust
protection, meets 400W need.
- **Selection Rationale:** The 1866-3120-ND PSU delivers 480W at 24V with high efficiency
(90%) and precise regulation (±0.24V), meeting the 400W max load with margin (20A vs.
16.7A). Its cost ($50) and size beat Linear’s inefficiency, LRS-350’s shortfall, Custom’s delay,
SE-600’s excess, and Battery’s impracticality, ensuring reliable power without thermal or
capacity issues.
#### 3.2.22 F1: 20A Fuse
- **Function:** Protects PS1 and wiring from overcurrent (>20A), tripping fast (<1s) at faults
(e.g., short circuit), rated for 480W at 24V plus margin. The 5x20 mm glass type fits standard
holders, with ~0.01 Ω resistance adding <0.2W loss at 16.7A, negligible for efficiency.
Ensures safety under industrial fault conditions (e.g., transducer failure).
- **Alternatives:**
- **15A Fuse:** Lower trip point.
- **25A Fuse:** Higher trip point.
- **Circuit Breaker:** Resettable, 20A.
- **10A Fuse:** Too low for load.
- **30A Fuse:** Too high for protection.
- **Comparison:**
- **15A:** $0.50, trips at 15A, ±10% (13.5-16.5A), risks nuisance trips at 16.7A (400W),
~0.015 Ω, <0.2W loss. Failure mode includes premature cutoff.
- **25A:** $0.50, trips at 25A, ±10% (22.5-27.5A), allows >480W, ~0.008 Ω, <0.2W loss,
risks delayed protection. Failure mode includes damage.
- **Breaker:** $5, 20A, resettable, ±5% (19-21A), ~0.02 Ω, bulkier (40x20 mm), costlier.
Failure mode includes mecha