A newly installed solar panel. Powered by stored solar energy, the device was a cost-efficient option for automating the opening and closing of storm pond water collection gates that were previously opened manually. Requiring 150 pounds of force to open, the hand cranks had caused several ergonomic concerns.

GEORGETOWN, KENTUCKY, (January 23, 2012) — TMMK has become adept at harnessing the power of Mother Nature. From composting our cafeteria waste to installing solar-fueled pond fountains along the Nature Trail-some very innovative projects have been undertaken thanks to a partnership between Facilities Control and Environmental Engineering. And recently the two groups got creative while resolving an ergonomic concern.

Twice a month an Environmental Specialist must test TMMK’s four storm water ponds for compliance with state storm water discharge standards. After it rains, the process requires the specialist to use 150 pounds of force to hand crank a gate which raises and lowers pond control valves. Over time, the ergonomic burden became a concern.

"We knew improvements were needed and realized the best way to open and close the gates safely was to use a motor, however, we needed electricity for a motor. And that’s where the challenge began,” said Heather Johnson, an Environmental specialist assigned to the project. “I began to price what it would cost to install electricity at all the ponds and would require over $40,000 for each of the four ponds."

That’s where Facilities Control Specialist Lannie Sproul and his experience with alternate energy resources proved helpful.

"From professional experience I knew we could install remote power using solar panels and batteries powered by the sun. And we could do it for about the tenth of the price of laying an electric line,” Sproul said.

In September 2008, a pilot was done in the Northeast pond located near NAPSC. Using solar panels connected to a DC powered battery the motorized gate controls sprung to life.

“Solar power is not particularly efficient, but remote applications are excellent opportunities” Sproul says. “The energy from the sun provides plenty of stored power to move the gates open or closed as needed. So much energy is stored in the battery that even on days with little sunlight  there’s enough power to operate the motor controls for up to five days.”

Environmental was so pleased with the result they decided to retrofit solar panels at the remaining ponds. The transition to solar panels at all pond locations is complete and there have been no further reports of ergonomic burden on team members operating the gates. Now instead of spending a painstaking 20 minutes at the hand crank, the gates open and close with the flick of a button.

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Contact:
Kerry Holt
Toyota Motor Manufacturing, Kentucky, Inc.
502-868-3577