510: Swing Gate Lock Improvement

Our sponsor, Ghost Controls, produces gate automation products for customers’ pre-existing swing gates. This project aimed to increase customer satisfaction with Ghost Control’s ZombieLock. The lock uses an electronic switch to close over a solid receiver pin for property security. Customers reported latching problems due to misalignments between latch and receiver, often caused by soft soil from harsh weather and gate sag.

To address this issue, we created a bolt-on attachment for the receiver that didn’t require changes to Ghost Controls’ current products. Our system included an attachable ramp and adjustable receiver plate. The ramp guided the lock into the receiver and reduced bounce when the gate closed. The adjustment plate allowed users to change the receiver’s height without tools.

We tested 3-D printed plastic models on 3-ft and 16-ft gates, adjusting the ramp angle and adjustment slot design based on results. After testing, we built parts from aluminum for strength and corrosion-resistance, powder-coating them black to match other ZombieLock products.

The new parts made it easier to adjust the system when misalignment prevented proper latching. With a 3.5-inch adjustment range, our product helped users fix their receivers to eliminate misalignment problems. Bouncing issues were solved through adjustability and dampening. This upgrade increased customer satisfaction through ease of adjustment and reduced bounce.