Streamlined Door Control for Large-Scale Farm Operations​

Streamlined Door Control for Large-Scale Farm Operations

By: Ed Vander Burgt

Ed Vander Burgt’s innovative deployment of ControlByWeb’s X-410 controller solves a persistent logistical challenge at a large farm repair shop, replacing unreliable wireless key FOBs with a robust, phone-driven automation system. This project underscores how industrial control solutions can streamline operations in demanding environments.

 

Background: Eliminating Key FOB Hassles

The farm’s repair shop manages 28 trucks and tractors requiring frequent access through two 30-foot service doors. Initially, wireless key FOBs were used to trigger door controls, but lost FOBs and dead batteries created constant delays. Employees wasted time searching for replacements, disrupting workflow.

 

Phone-Based Door Control

The X-410 controller was installed to interface with the existing door mechanisms. Its four relay outputs wire directly into the shop’s door control buttons, mimicking FOB signals. Door status sensors (open/closed) connect to the X-410’s four digital inputs, providing real-time feedback. Employees now use the ControlByWeb mobile app—loaded with a preconfigured file—to trigger doors from their phones. This eliminates physical FOBs entirely, leveraging a tool every worker already carries.

 

Operational Benefits

The system sends email alerts to management if doors remain open after hours or exceed predefined open-time thresholds, reducing security risks and energy waste. Managers verify door status remotely via the app, ensuring compliance with safety protocols. By removing FOBs, the farm avoids battery replacements and hardware costs while simplifying access for seasonal workers.

 

Technical Implementation

  • X-410 Relays: Activate door motors via dry-contact signals, parallel to existing buttons.

  • Digital Inputs: Monitor door position sensors for status tracking.

  • Mobile App: Employees access door controls through a secure, intuitive interface.

  • Email Notifications: Custom alerts for after-hours openings or prolonged door activity.

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Future-Proof Scalability

The X-410’s Peer-to-Peer (P2P) capability allows integration with additional ControlByWeb devices, such as security cameras or environmental sensors. Spare relays and inputs could support features like automated lighting or HVAC activation when doors open.

 

Conclusion

Vanco Electrical Solutions commends Ed Vander Burgt’s practical use of the X-410 to modernize farm operations. By replacing fragile FOBs with smartphone control and real-time alerts, this project enhances efficiency, security, and cost-effectiveness—proving that industrial automation can solve everyday frustrations. Thank you, Ed, for your submission!