Ghost Controls manufactures automatic gate and garage door openers and is launching a new residential product line requiring pre-shipment testing to ensure proper functionality. Current testing methods use full garage door systems, consuming significant floor space while increasing setup time and costs. We designed a compact testing device that replaces the large setup while maintaining comprehensive quality verification.
Our system tests garage door openers without damaging units or affecting their sale condition. Workers place units into a sliding drawer and initiate tests using simple button controls and a display screen. The tester automatically verifies motor operation, button functionality, lighting, audio alerts, and safety features. Internal sensors measure each function while small motors simulated button presses. A sensor, magnet, and wheel measures motor speed and direction, comparing measurements against specification values to identify defects such as weak motors or electrical faults. We implemented a smart camera to verify light color and location, while a dedicated sensor detects and measures sound alerts. The system tests safety detection by breaking a light beam, confirming the opener properly stopped or reversed when detecting obstructions.
We isolated the testing environment from external light and noise to ensure consistent results. After each test cycle, the device clearly indicated pass or fail status. All components fit within the drawer assembly to minimize spatial footprint and improve factory floor usability. The result is a compact, repeatable testing system that enables workers to test more units per day with consistent results. This design helps Ghost Controls improve quality assurance processes, decrease testing costs, and increase confidence that each garage door opener meets performance expectations before shipment.
