Custom Gate Automation Sydney: From Underground Motor Constraint to a New Solution in Pymble
Replacing an automatic gate motor is not always as simple as removing the old operator and installing another one in the same position.
A recent project in Pymble, Sydney provided a good example.
The property had an existing underground swing gate automation system. The motor had provided years of service but had reached the end of its useful life and required replacement.
A like-for-like underground replacement was technically possible.
However, once the project requirements were considered more carefully, simply installing another underground motor was not necessarily the most practical solution.
The client had two important requirements:
the project needed to be completed within a relatively short timeframe; and
the overall cost of the works needed to remain economical.
Our task therefore became more than selecting another gate motor.
We needed to determine whether the existing gate could be automated in a different way.
The Existing Underground Gate Automation
Underground gate motors are popular because most of the automation mechanism is hidden below the gate.
When correctly designed and installed, they can provide a very clean appearance.
However, replacing an ageing underground system can involve considerably more work than replacing a conventional above-ground motor.
Depending on the existing installation, works can include:
accessing and excavating around the underground motor box;
removing the existing motor and associated components;
preparing or repairing the motor foundation;
concrete works;
making sure the underground housing is correctly positioned;
providing suitable drainage around the motor installation;
protecting the equipment from long-term moisture exposure;
reinstalling and aligning the gate;
rewiring and commissioning the automation system.
The underground environment is particularly important.
Drainage needs to be considered carefully because water accumulating around an underground motor can contribute to corrosion and deterioration over time.
For this Pymble project, repeating the existing underground arrangement would therefore have involved considerably more civil and installation work.
The Site Constraint
The existing gate itself was still suitable for continued use.
The main problem was the ageing underground automation.
The obvious approach would have been:
Remove the existing underground motor and install another underground motor.
But that approach needed to be assessed against the client's timeframe and project budget.
Rather than assuming that the original automation design had to be repeated, the gate geometry and structure were reviewed to determine whether an alternative operator could be used.
This is an important part of automatic gate design.
The best replacement motor is not necessarily the motor that looks most similar to the one being removed.
Gate geometry, hinge position, available mounting locations, gate construction, opening angle and site conditions all need to be considered.
Considering an Alternative Gate Automation System
After reviewing the existing gate configuration, an articulated-arm swing gate automation system was selected as the alternative approach.
Articulated-arm operators are installed above ground and use a jointed arm to transfer movement from the motor to the gate leaf.
For this particular gate, however, the new motors could not simply be bolted into position.
The existing gate structure had originally been designed around underground automation.
The mounting geometry therefore needed to be adapted.
Custom Brackets and Gate Modifications
To accommodate the new articulated-arm system, custom mounting arrangements were required.
Brackets and associated gate modifications were designed so that the new motors could operate the existing gates correctly.
These components were then fabricated specifically for the installation.
This was one of the most important stages of the project.
Installing a powerful motor does not compensate for poor geometry.
The position of the motor, articulated arm, gate hinge and mounting bracket all affect how forces are transferred through the gate during opening and closing.
Getting these dimensions correct helps achieve smooth gate movement and avoids unnecessary stress on the automation.
Why the Alternative Solution Made Sense
The new approach significantly reduced the amount of work that would otherwise have been associated with another underground installation.
Instead of carrying out extensive excavation and underground civil works, the project could focus on:
adapting the existing gates;
fabricating the required brackets;
installing the articulated-arm motors;
configuring the automation;
adjusting the gate movement; and
completing testing and commissioning.
The original project notes estimated that the alternative solution resulted in a project budget at least around half the cost of the like-for-like underground approach.
Importantly, the solution also addressed the client's timeframe.
The conversion was completed in approximately three days.
Installation and Commissioning
Once the custom mounting components had been prepared, the articulated-arm automation system was installed onto the existing gates.
The installation then required the usual setup and commissioning process.
This included checking the physical gate movement and ensuring that the new automation operated correctly through its opening and closing cycles.
Commissioning is an important part of any gate automation project.
The job is not finished when the motors have simply been mounted.
The complete system needs to operate smoothly and consistently under real operating conditions.
The Final Outcome
The completed project provided the Pymble client with an alternative to repeating the previous underground installation.
By reconsidering the original automation design, it was possible to avoid much of the excavation, concrete work and underground preparation that a like-for-like replacement would have required.
The final solution:
retained the existing gates;
replaced the ageing underground automation;
introduced articulated-arm operators;
used custom-designed and fabricated mounting components;
reduced the extent of underground civil works;
reduced the overall project cost compared with the proposed like-for-like approach; and
allowed the installation to be completed in approximately three days.
Why Gate Automation Replacement Should Start With an Assessment
This project highlights an important principle in automatic gate work:
Replacing an existing motor does not automatically mean replacing it with the same type of motor.
Sometimes like-for-like replacement is absolutely the correct solution.
Other times, the gate, site conditions, client requirements or cost of associated works make another approach more practical.
Before making that decision, several factors should be considered:
Gate condition
The gate itself needs to be structurally and mechanically suitable for automation.
Gate geometry
Hinge positions, gate dimensions and opening requirements influence which motors can operate correctly.
Existing infrastructure
Power, cabling, control equipment and existing civil works should be considered.
Site conditions
Drainage, ground conditions, available mounting space and driveway configuration can affect the installation.
Project timeframe
Some automation solutions involve substantially more fabrication or civil works than others.
Long-term serviceability
Future maintenance and access to components should also be considered when selecting the replacement system.
Custom Gate Automation Is Often About Problem Solving
Complex gate automation projects are rarely solved by choosing a motor from a catalogue.
The operator is only one part of the overall system.
Good automation design considers the gate, structure, geometry, access requirements, safety equipment, site environment and how the system will be maintained in the future.
In the Pymble project, changing from underground automation to an articulated-arm system required additional engineering and fabrication at the beginning of the project.
But that design work ultimately allowed a more practical solution to be delivered within the client's timeframe and budget.
That is often where the real value of a custom gate automation solution lies.