In commercial and industrial settings, roll-up doors are crucial for efficient access control and security. Installing automatic roll-up doors with motion sensors can significantly increase security and operational effectiveness. Roll-up doors are commonly found in garages, warehouses, and other business facilities. They can be protected using a variety of methods to enhance security and prevent unauthorized access. Because motion sensors can be controlled by a password, only authorized individuals can access the door. If the system detects a potential intruder, it can sound alarms or notify security personnel, enabling a timely response. However, ensuring the reliable operation of these doors is paramount to maintaining safety and operational continuity. One essential aspect of enhancing the reliability of roll-up doors is the integration of fault alarm systems. These systems monitor the doors operation in real-time, promptly detecting any malfunctions or abnormalities that could compromise safety or disrupt operations. By providing early warning alerts, alarm systems enable proactive maintenance and intervention, minimizing downtime and ensuring the smooth functioning of roll-up doors. Thus, the integration of alarm systems represents a critical advancement in optimizing the reliability and safety of roll-up doors in various industrial and commercial applications (Naim et al., 2023). 

The integration of advanced technologies such as motion sensors and alarm systems into automatic roll-up doors represents a significant advancement in access control and security management. Automatic roll-up doors have become indispensable in industrial and commercial environments, offering seamless entry and exit while enhancing security measures. However, traditional access control methods, such as keys or access cards, are susceptible to theft, loss, or duplication, highlighting the need for more secure alternatives. By incorporating biometric authentication, particularly fingerprint recognition, these doors offer a highly secure and reliable means of access control, mitigating the risk of unauthorized entry. Furthermore, the inclusion of alarm system adds an additional layer of safety by promptly detecting and alerting to any malfunctions or abnormalities within the door mechanism, ensuring uninterrupted operations and personnel safety. These doors streamline access control procedures, enabling authorized personnel to enter and exit premises seamlessly while minimizing the risk of unauthorized entry. The incorporation of biometric authentication, particularly fingerprint recognition, addresses significant vulnerabilities associated with conventional access control methods such as keys or access cards (Yu et al., 2023). 

Automatic roll-up doors integrated with motion sensors and alarm systems, according to Marasco and Ross, (2014) have become indispensable in industrial and commercial environments, offering heightened security and operational efficiency. Moreover, Li et al. (2020) asserted that the integration of alarm system enhances the reliability and safety of the door mechanism by promptly detecting and alerting to any malfunctions or abnormalities. Biometric authentication, especially motion sensors, provides a secure and reliable means of access control (Conti, 2017; Mamun et al., 2020). Unlike traditional methods being susceptible to theft or duplication, fingerprints offer unique identification for individuals, reducing the risk of unauthorized access. By integrating fingerprint recognition technology into automatic roll-up doors, organizations can bolster security measures while simplifying access management processes, enhancing overall operational efficiency and safety.  Integrating a fault alarm system complements the security features of automatic roll-up doors by continuously monitoring their operation (Muroi et al., 2020). This system detects anomalies such as sensor failures, motor malfunctions, or obstacles obstructing the doors path, triggering an alarm to notify administrators or maintenance personnel promptly. Such proactive fault detection and notification mechanisms are crucial in preventing accidents or disruptions to operations, ensuring the smooth functioning of the door system (Villanueva et al., 2023).

Additionally Ashour, (2004) posited that in order to give students effective industrial instruction and enhance their practical skills through the ongoing development of laboratory industrial resources, sophisticated manufacturing technology is crucial to the curriculum of industrial engineering education. As an industrial case study for the students enrolled in the industrial automated systems course, the author has created an Automatic Transfer Switch (ATS) based on a Programmable Logic Controller (PLC) in the Arab Academy for Science and Technology (AAST) laboratory. The ATSs general principles and useful applications have been covered. System requirements, sensors, actuators, hardware configuration, software programming, and experimental testing are all examples of the steps involved in creating and putting the suggested setup into practice. Developing and implementing an automatic roll-up door using motion sensitivity with an alarm system requires interdisciplinary collaboration among experts in biometrics, sensor technology, automation, and safety systems. Furthermore, understanding user requirements and preferences is essential for the successful deployment of the system, underscoring the importance of user feedback and iterative design processes (Baballe et al., 2021).  

Conversely Jeong and Bae, (2014) noted that the integration of motion sensor technology with automatic roll-up doors, complemented by the alarm system, represents a significant advancement in access control and security management. By amalgamating biometric authentication with real-time fault detection and alarm capabilities, the system offers unparalleled security, efficiency, and reliability, rendering it as well-suited for a myriad of industrial and commercial applications. 

The ease of usage and compact design of roll-up doors made them popular in commercial and industrial environments. To facilitate easy access for personnel and vehicles, these doors are frequently opened automatically by motors and sensors. Roll-up doors are susceptible to errors and malfunctions, just like any mechanical system, which can pose a risk to public safety and cause difficulties with operations. Despite the potential benefits of automatic roll-up doors using motion sensitivity with alarm system, there is a noticeable gap in understanding the long-term reliability and effectiveness of these systems in real-world applications. While existing studies provided insights into the technical aspects and immediate benefits of such systems, there was a lack of comprehensive research on their composition, operating performance, and safety in diverse environments. Therefore, further research is needed to address this gap and provide actionable insights for developing and deploying automatic roll-up doors with enhanced security features. This study was done to enhance the safety and dependability of automatic roll-up doors by designing and implementing a malfunction alarm system. The purpose of this study was to develop a prototype automatic sensor roll-up/ down door with alarm system. Specifically, it aimed to describe the prototype automatic sensor roll-up/ down door with alarm system in terms of technical features; determine the operating performance of the device in terms of time in seconds in opening and closing of the door; determine the sensitivity of device in three varying distances such as 2 meters, 4 meters, and 6 meters distances, and the audibility of the alarm system; and determine the level of acceptability of the developed prototype automatic sensor roll-up/down door with alarm system in terms of composition, operating performance, and safety.

The automatic sensor roll-up/down door with alarm system was intended to improve accessibility and security, while offering the ability to detect faults and force entry of the intruder.  The developed device also detected moderate motion such as from cars, forklifts track, and people within a specific range.  The automatic sensor roll-up/down door with alarm system was evaluated according to its design criteria such as: 1) the circuit of the device was properly connected; 2) the push button controller of the device was properly connected; 3) AC motor runs and reduces Revolution Per Minute (RPM) of the reducer gear; 4) turn on the push button switch of the device for forward reverse operation; 5) start the convenience operation of the product; 6) the device was tested for its operating performance through actual observation, the data were accurately recorded and analyzed using appropriate test measurements; and 7) used proper manual operation.

The design was the product of the continuous effort of the researcher in imagining and visualizing a device suitable to answer the way of operating the product to perform the required job easily and efficiently. The automatic sensor roll-up/down door with alarm system was assembled using a methodical procedure that complied with the occupational health and safety procedure, which was done as follows:

Step 1 involved the designing of the block diagram of the developed device as shown in Fig. 1.  A block diagram is a visual depiction of a system, project, or situation that demonstrates the connections between its many components (Miller & Granger, 1982). Parts and accessories were specified and arranged according to the electrical diagram and created plan. The block diagram helped the researcher put the device together by showing how the various components of the circuit should be connected. The design was the product of the continuous effort of the researcher in imagining and visualizing a device suitable to answer the way of operating the product to perform the required job easily and efficiently. The automatic sensor roll-up/down door with alarm system was assembled using a methodical procedure that complied with the occupational health and safety procedure, which was done as follows:

Step 1 involved the designing of the block diagram of the developed device. A block diagram is a visual depiction of a system, project, or situation that demonstrates the connections between its many components (Miller & Granger, 1982). Parts and accessories were specified and arranged according to the electrical diagram and created plan. The block diagram helped the researcher put the device together by showing how the various components of the circuit should be connected.

Fig. 1: Schematic diagram of automatic sensor roll-up/down door with alarm system.

Step 2 involved the tools, materials, and equipment required to build the device. To guarantee user safety, the instruments underwent extensive testing and calibration. The device was constructed using a variety of tools, such as a bench vise, welding machine, close and open wrench, cutting tools like hacksaws and cutting disks to cut the metal railing, driving tools like Phillips and standard screwdrivers, boring tools like electric drills to bore holes, and various pliers like long-nose pliers and side-cutting pliers. Electrical materials contained bulbs, switches, wires, conduits, a junction box, a utility box, and a buzzer. The control panel also contained a circuit breaker, contactors, relays, selector switch, push button switch, indicator lights, emergency stop button, and limits switch.

The equipment used in making the automatic sensor roll-up/ down door with alarm system contained an Arduino Uno kit that held the different electronic components and was soldered to the circuit board using a soldering iron. The various components were then pre-checked with a multi-meter to make sure they were all functioning properly. The control panels managed the automated processes of the device and enabled the motion sensor to detect motion and roll up and down the door. The automatic transfer switch transferred power when it detected a power failure or significant voltage drop. The electrical equipment AC motor was used as a prime mover of the device and the reducer gear motor provided torque amplification and speed reduction for improved performance and efficiency.

Step 3 involved the Arduino Uno, which had 14 digital input/output pins, 6 analog inputs, a USB connection, a power jack, and a reset button. It was based on the ATmega328P microcontroller and could be programmed with the Arduino IDE.

In Step 4, the different components of the controller were assembled on the Arduino Uno circuit board to ensure secure mounting and reliable connections. This step helped keep the components in place under various conditions and prevented loose connections. The controller board was powered by a 7V, 1.5A DC power supply for functional testing. Manual tests were then conducted using push-button switches, which created an audible sound upon activation, confirming the modules successful operation.

Step 5 involved the downloading of the Arduino Uno software and connecting and configuring Arduino Uno to the computer. Write the program using the Arduino programming language (which is a simplified version of C/C++).

Step 6 entailed the meticulous assembly of the developed devices joining parts such as automatic switches, AC Motor, reducer gear Motor, Arduino Uno, and control panel connected with circuit breakers (CBs), magnetic contactors, and relays. To guarantee safe functioning, numerous parts were assembled and then given clear labels and warning symbols. Thorough electrical inspections were carried out to confirm the devices overall performance and the integrity of all connections. Lastly, the developed device, together with other necessary parts like the conduit connectors and ground bus bar, was firmly installed within the electrical box. A multi-meter was used to check for electrical leakage between the exposed metal pieces and the electrical box in order to increase safety. 

The device was evaluated based on actual observations and evaluation by evaluators using a researcher-made questionnaire. The questionnaire underwent validation by experts and members of the research advisory committee. The steps in evaluating and rating the device according to the observation and analysis were as follows:

To evaluate the operating performance of the developed device in terms of time in opening and closing of the door, the researcher did the following set up according to specification: tested the opening time, in second, of the door by activating the sensor and observing how quickly the door opened after detecting movement using a stopwatch to measure the time it took for the door to fully open from the moment the sensor was triggered; tested the closing time, in second, of the door by moving away from the sensor to trigger the closing sequence; measured the time it took for the door to fully close from the moment the sensor detected the absence of an obstacle; and repeated the procedures 10 times to ensure consistency of results and recorded the observed data in the record sheet.

To evaluate the motion sensitivity of the developed device into three varying distances, such as 2 meters, 4 meters, and 6 meters, the researcher did the following: assembled the accessory or components; placed an object or target at each of the three distances (2 meters, 4 meters, and 6 meters) from the sensor to simulate a potential obstacle that the sensor should detect; activated the automatic sensor roll-up/down door system and observe how the sensor responds to the presence of the object at each distance; noted the sensitivity of the sensor at each distance; and repeated the procedures 10 times to ensure consistency of results and recorded the observed data in the record sheet.

In evaluating the audibility of the developed device in three varying distances, such as 2 meters, 4 meters, and 6 meters, the researcher did the following: assembled the accessory or components; placed an object or target at each of the three distances (2 meters, 4 meters, and 6 meters) from the device to simulate the audibility of sound; activated the automatic sensor roll-up/down door system and observed how audible to each distance; note the audibility of sound at each distance; and repeated the procedures 10 times to ensure consistency of results and recorded the observed data in the record sheet.

To test the general acceptability of the developed device in terms of technical features, composition, operating performance, and safety, the researcher-made questionnaire was utilized. A total of 30 evaluators were included since they were the only available evaluators during the conduct of the evaluation. There were 13 industry evaluators with two (2) electrical engineers from Capiz Electric Cooperative, Inc. (CAPELCO), two (2) mechanical engineers from San Miguel Brewery Inc., two (2) bodega supervisor, three (3) forklift operators from San Miguel Brewery Inc., two (2) forklift operators from Coca-Cola Distributor, and two (2) electronics technicians and electricians of Northern Iloilo State University (NISU).  There were 16 evaluators from the academe with eight (8) from NISU, comprising three (3) electrical engineers and one (1) electronics engineer, two (2) mechanical engineers, two (2) professors/instructors. The other eight (8) evaluators were from Capiz State University (CapSU), comprising three (3) electrical engineers, three (3) professors/instructors, two (2) research examining committee members, and one (1) end-user evaluator, a garage owner.

Industrial experts, academic professors, and end-users carried out the testing of the developed device. Multiple rounds of testing were conducted to achieve its optimal performance. A trial-and-error approach was employed and the insights of the experts were integrated. 

The instruments used in this study were categorically divided into two. The first one was the instrument to evaluate the time per second of the opening and closing of the roll-up/ down door.  The sensitivity of the motion sensors, the effectiveness of the 2-meter, 4-meter, and 6-meter distances that the Alternating Current (AC) motor could work forward and reverse, and the limit switch control, the circuit to stop and run the AC motor ere tested.  The audibility of the sound of the bell during the forced entry of the intruder was the effectiveness of the 2 meters, 4 meters, and 6 meters distances.  These electrical measuring instruments were the wattmeter and stopwatch.  Utilizing binary scoring statistics, it was completed to a quality description. The second one was the researcher-made instrument, which the composition, performance operation, and safety of the developed device were evaluated through the guided items rated using the evaluation sheet.  It was subjected to a quality description using the three (5) point Likert scale in scoring the variables.

The data to be gathered in this study will be the actual results of finding the technical features of time in seconds of opening and closing the door.  The sensitivity of the photoelectric/proximity sensor in terms of the 2-meter, 4 meters, and 6 meters distances of the device, the audibility of alarm of automatic sensor roll-up/down door with fault alarm system, and the result of the respondents evaluation of the products acceptability in terms of composition, operating performance, and safety.

To evaluate the operating performance of the device in terms of time in opening and closing of the door the researcher will do the following Set up the automatic sensor roll-up/down door system with the fault alarm system according to specification; test the opening time in the second of the door by activating the sensor and observing how quickly the door opens after detecting movement using a stopwatch to measure the time it takes for the door to fully open from the moment the sensor is triggered; test the closing time in second of the door by moving away from the sensor to trigger the closing sequence; measure the time it takes for the door to fully close from the moment the sensor detects the absence of an obstacle; repeat the procedures ten (10) times to ensure consistency of results, and record the observed data in the record sheet. To evaluate the motion sensitivity of the developed device into three  (3) varying distances such as 2 meters, 4 meters, and 6 meters, the researcher will do the following: assemble the accessory or components; place an object or target at each of the three distances (2 meters, 4 meters, and 6 meters) from the sensor to simulate a potential obstacle that the sensor should detect; activate the automatic sensor roll-up/down door system and observe how the sensor responds to the presence of the object at each distance; note the sensitivity of the sensor at each distance; repeat the procedures ten (10) times to ensure consistency of results, and record the observed data in the record sheet. In evaluating the audibility of the device in three varying distances such as 2 meters, 4 meters, and 6 meters, the researcher will do the following: assemble the accessory or components; place an object or target at each of the three distances (2 meters, 4 meters, and 6 meters) from the device to simulate the audibility of sound; activate the automatic sensor roll-up/down door system and observe how audible to each distance; note the audibility of sound at each distance; repeat the procedures ten (10) times to ensure consistency of results, and record the observed data in the record sheet. To test the general acceptability of the device in terms of technical features, composition, operating performance, and safety, the researcher-made questionnaire was utilized. 

The basis for analyzing the cost of the product was the cost of materials and forty (40) percent of the labor cost. 

The prototype automatic sensor roll-up/down door with alarm system demonstrated several technical features that improve user control and security. Controlled by the Arduino Uno application, the device efficiently detected intruders and notified users of forced entries. Its components included an electric motor with a 2.2 kVA rating, a single-phase motor with a voltage of 220 volts, a speed of 2800 RPM, a capacitor value of 15 µF, a current of 13.3 A, and a frequency of 50 Hz. The automatic transfer switch was a dual power supply with a reduction ratio of 50:1. The control circuit used an Arduino Uno R3 board that contained necessary parts such as indicator lights, an emergency stop switch, and a magnetic contactor. The alarm system was equipped with three alarms: one for motor control issues, one for forced entry detection, and another one for the requirement of a password for the doors opening and closing.  The motion sensor and limit switch made up the automated sensor. 

Fig. 2: Technical features of the automatic sensor roll-up/down door with alarm system.

Technical Features 

1. AC Motor

2. Reducer Gear Motor

3. Automatic Transfer Switch

4. Arduino Uno programmable device

5. Control Panel

6. Alarm System

7. Automatic Sensor

After 10 trials, the automatic sensor roll-up/down doors operational performance was evaluated, and it was found to consistently open and close in 15 seconds. A mean time of 15 seconds, which was considered rapid, supported this performance. The finding also indicated that the Arduino Uno program successfully sent commands to the device, indicating its operational efficiency. The door mechanisms responsiveness and dependable operation were indicated by the regular timing. The result implies that the developed device is properly receiving the command from the Arduino Uno application or software. This indicates that the device is fast at opening and closing the door. This clearly shows that it took 15 seconds of opening and closing the door of the automatic sensor roll-up/ down door with alarm system.

This finding was in consistent with the research conducted by Suravase et al. (2021), who developed the automation of door opening and closing. They created a system for doors (home or college doors) to open and close automatically. When the door is open, the doors sensor is cut, causing a mechanism to open the door and then automatically close it. Because people cannot physically touch the door, it would help stop or slow the spread of pandemic disease. Their invention also used an Arduino and an ultrasonic sensor to detect human presence and automatically open and close doors. The door automatically opens when someone walks up to it (approximately 2 or 3 feet away), then it closes by turning back in the opposite direction after a few seconds (5 to 10 seconds). These automated door opening and shutting systems are highly helpful since they eliminate the need for someone to wait outside the door and open it for visitors.

The finding further showed that the device was sensitive at both 2, 4, and 6 meters. The devices mean sensitivity score was 1, indicating high sensitivity, after achieving a total score of 10 in 10 trials. The automated door operated dependably and reacted to motion efficiently at all tested distances. When the alarm system detected forcible entry, it successfully generated a sound audible at all tested distances. The finding also demonstrated that the automatic sensor roll-up/down door with alarm system can be function both manual and automatic. The result implies that the device is properly receiving the command from the Arduino Uno application or software. This indicates that the device is sensitive to motion sensitivity and reacts to motion efficiently at all tested distances. This means that the developed can be controlled effectively in two (2) m, four (4) m, and six (6) m distances using motion sensitivity.

The study of Nwafor et al. (2024) found that after the siding door was put together and put through a functional test, it was found that the automated sliding door could identify both people and things. Once the object had left the designated 50-cm detecting range, the motor would open and close the door. In Nigeria, this work is a positive step toward fostering local innovation. The developed device in terms of composition, operating performance, and safety was very acceptable in each factor of evaluation.

The findings on the acceptability of automatic sensor roll-up/ down with alarm system in terms of composition, operating performance, and safety imply that it is very acceptable as it has components that reflect careful planning, arranged, and secured correctly, and with sensors that sensitively detect motions. This also entails that the developed device performed effectively as designed and is safe to operate continuously. The study aligned with Shyr et al. (2024), who assessed the variables affecting students acceptance of augmented reality in an automated system. According to the findings, there was no discernible relationship between perceived usefulness and ease of use when it comes to using augmented reality. Perceived usefulness had a considerable impact on students behavioral intention to utilize augmented reality, although perceived ease of use had a positive impact. Interestingly, in the case of augmented reality instruction, the perceived utility showed a strong correlation with both behavioral intentions to use and attitude toward use. Furthermore, in the context of automation systems with augmented reality, students attitudes toward utilization were positively impacted by perceived ease of use. Additionally, no significant correlations were found between behavioral intention to use and attitude toward use, or between perceived utility and ease of use when it came to using augmented reality.

The prototype automatic sensor roll-up/down door with alarm system demonstrates several technical features that improve user control and security. It efficiently detects intruders and notified users of forced entries. The door mechanisms responsiveness and dependable operation are indicated by the regular timing. The automated door functions consistently and responds to motion efficiently at all tested distances with high sensitivity level. The audibility is quite good in spotting forced entrance by a burglar. The alarm systems ability to reliably warn of possible security risks is demonstrated by the clear sound it produces at all tested distances. The device demonstrates notable improvements in security and user control. A complete security solution is also offered for motor control issues, for forced entry detection, and for the requirement of a password for the doors opening and closing. This prototype lays the groundwork for future advancements in automated access control systems in addition to proving that automated security measures are feasible. The device is effectively receiving commands from the Arduino Uno application, ensuring reliable functionality. The performance data confirms the doors swift operation and effective communication with the control system, highlighting its suitability for environments requiring prompt access. The device operates both automatically and manually. 

The researcher appreciates those who contributed their valuable support on this endeavor, particularly to the evaluators, Capiz State University Main Campus, and Northern Iloilo State University, Victorino Salcedo Campus, Sara Iloilo, Philippines.

The author affirms that there are no conflicts of interest.