Abstract

Our sponsor, Ghost Controls, is a company that produces gate automation products for customers’ pre-existing swing gates. The goal of this project is to increase customer satisfaction with Ghost Control’s ‘ZombieLock’. The lock uses an electronic switch to close over a solid receiver pin and is aimed to add security to properties. Over time, customers report problems with latching due to misalignments between the latch and receiver. Soft soil due to harsh weather and gate sag often causes this issue. To address this issue, we created a bolt-on attachment for the receiver. That means this product will not require any changes to Ghost Controls’ current products. Our system includes an attachable ramp and adjustable receiver plate. The ramp guides the lock into the receiver and reduces bounce when the gate closes. The adjustment plate allows users to change the receiver’s height without the use of tools. We tested 3-D printed plastic models on 3-ft and 16-ft gates. Based on these tests, we adjusted the ramp angle and the adjustment slot design to function better. This iterative process allowed the team to produce a functional and reliable product. Once the testing was done, we built the parts from aluminum, a light, strong, and corrosion resistant material. To add visual appeal, the parts were powder coated to match the other products in the ZombieLock line that are black in color. The new parts help the ZombieLock function by making it easier for people to adjust the system when misalignment issues prevent proper latching. With a total adjustment range of 3.5 inches, our product helps people to easily fix their receiver to get rid of the misalignment problem on their gate. Bouncing and any misalignment which prevents proper latching issues are not a problem because of the adjustability and dampening offered by the design. In conclusion, this upgrade increased customer satisfaction through ease of adjustment and reducing bounce.

01 Reliable Engagement

The system should be able to work with the current Ghost Controls platform and lock shut in a reliable manner, similar to the current ZombieLock.

02 Enhanced Durability

The sytem needs to be constructed to withstand harsh environments. These include freezing winters, blazing hot summers, and extreme winds.

03 Ease Of Installation

The system should be trivial to install for the regular DIY'er. Provided the user has the correct tools, intallation instructions should be clear and concise.

Our Solution

Our solution to the customers' problem was a ramp and adjustment plate combination manufactured from powdercoated aluminum.

Design Proccess

Iterative engineering design methods were put to use in conjunction with technical testing measures such as FEA and stress/strain analyses

  • All Content
  • Prototyping
  • Testing
  • Final Product

Original Ramp Design

To be joined with double-sided tape, lacked strength

Final Ramp Design

Stronger structure to be fastened to reciever with screws. Ramp angle lowered and drainage holes added for moisture evacuation

Original Plate Design

Only worked on right-swinging gates, lacked strength

Final Plate Design

Works with both left and right-swinging gates. Gussets and improved track design provide strength

Original Ramp Model

The first ramp design in physical form

Final Ramp Model

The final ramp design in physical form

Original Plate Model

The first plate design in physical form

Final Plate Model

The final plate design in physical form

Full Model

The ramp and adjustment plate on a modeling structure

Full Model Outside

The ramp and adjustment plate on a testing structure

Misaligned Testing Gate

4-Foot model gate provided by Ghost Controls, demonstrating misalignment

Standard Reciever

4-Foot testing gate with standard ZombieLock receiver

Ramp and Adjustment Plate

4-Foot testing gate with our modified ZombieLock reciever

Ramp and Adjustment Plate

4-Foot testing gate with our modified ZombieLock receiver from the side

Final Cad Design

The final CAD assembly with the current ZombieLock receiver attached

Final Product

Final product machined from AL 6061

Team 510

Meet the Mechanical Engineering Undergraduates who made it happen

Kayla Boudreaux

Project Manager

Kayla will graduate in Spring 2025 with a Bachelor's of Science in Mechanical Engineering. Upon graduation she will commission as an officer in the United States Air Force.

Jacob Brock

CAD Engineer

Jacob will graduate in Spring 2025 with a Bachelor's of Science in Mechanical Engineering. He will begin his career as an Associate Engineer with Florida Power and Light in Northwest Florida.

Ernest Patton III

Manufacturing Engineer

Ernest will be graduating this May, 2025 with a Bachelor's of Science in Mechanical Engineering. He hopes to land a role within the aerospace or defense Industries this upcoming summer.

Dior Reece

Test Engineer

Dior is a senior Mechanical Engineering student graduating in Spring 2025. After graduation she hopes to pursue a career within the aerospace industry.

Olivia Walton

Design Engineer

Olivia will graduate in Spring 2025 with a Bachelor's of Science in Mechanical Engineering. After graduation she hopes to pursue a career in the marine engineering industry.

Bradley Wiles

Materials Engineer

Bradley will graduate in Spring 2025 with a Bachelor's of Science in Mechanical Engineering. After graduation he hopes to pursue a career in the infrastructural engineering industry.

Deliverables

Listed below are documents developed by the team about and for this project

Design Reviews

Virtual Design Review 1 - October 2024

VDR1

Virtual Design Review 2 - November 2024

VDR2

Virtual Design Review 3 - December 2024

VDR3

Design Review 4 - January 2025

DR4

Design Review 5 - February 2025

DR5

Design Review 6 - March 2025

DR6

Acknowledgements

This project would not be possible without the continued support from these parties

Darryl Beadle

Chief Engineer - Ghost Controls

Darryl founded Ghost Controls and now acts as the head mechanical engineer. Darryl was our primary source of contact throughout the project and very helpful in solving technical problems.

Mickey Nguyen

Chief Engineer - Ghost Controls

Also a founder and now the head electrical engineer at Ghost Control. Mickey was an alternate source of contact and served to assist the team in any electrical matters throughout the project.

Dr. Shayne McConomy

Senior Design Professor

As the Senior Design professor, Dr. Shayne McConomy help to coordinate the project and developed checkpoints for students to maintain steady progess until project culmination. He also served as a consulting source for the team.

Dr. Simone Hruda

Project Advisor

Dr. Simone Hruda was the in-house advisor for the team at the FAMU-FSU College of Engineering. With routine meetings she provided the team with technical engineering expertise and helped foster new ideas.

Future Work

  • February 2025
    Machine Shop
    The material and prototyped model along with its corresponding drawings and file package will be brought to the machine shop at the FAMU-FSU College of engineering to be manufactured.
  • March 2025
    Hardware
    The hardware to be used with the manufactured design is to be finalized and purchased.
  • March 2025
    Finishing
    Once the design has completed manufacturing in the machine shop, it will be taken to a supplementary facility in which it will be powdercoated to match the rest of the existing system.
  • April 2025
    Testing
    The finished design will be tested in the same fashion that the original prototype was tested to validate our assumptions.
  • April 10, 2025
    Engineering Design Day
    Engineering Design Day will take place on April 10, 2025. The team will present the final product with the prototype and an accompanying poster at the College of Engineering.
  • May 3, 2025
    Conclusion
    On May 3, 2025 the team will be graduating from the FAMU-FSU College of Engineering with Bachelors' of Mechanical Engineering, thus concluding their undergraduate education. .