Streetlight Controller

The Challenge

This street light controller senses when the sun goes down and turns on the street light. There are many controllers like this being used currently. What makes this device unique is that it contains sensors to detect when the street light is out and if the light pole is down, or has been struck by a car. The device contains a cell phone modem and GPS, and is able to call into a center to report when it needs replacing. This saves time by removing the need for visual inspection and reduces light outage time.

The Solution

Pongratz Engineering designed the entire device except for RF and Electrical Engineering elements. The electrical and software was designed with a partner electrical engineering firm. The case has an o-ring seal to protect the electronics from severe storms and environmental challenges. Pongratz Engineering sourced a special foam silicone gasket that was used to create a seal between the face of a NEMA three blade socket and the base of the device. Pongratz Engineering designed all the plastic injection molded parts and brass contact blades for the NEMA socket. Once the databases and documentation were created, everything was transferred to the client. The client had tooling built and handled manufacturing logistics issues. Pongratz Engineering provided support to transition the device into manufacturing.

Pongratz Engineering also researched which injecting molded resin to use that would be UV resistant and could take the full range of environmental temperatures the device needed to withstand. The plastic resin also needed to pass UL flame rating requirements. Using finite element analysis (FEA), all snap-lock joints were stress-analyzed to ensure a proper fit and assembly force.