Fiber Composite Materials Gas Detection Solutions: Nexisense Ensures Safe and Efficient Manufacturing

Fiber composite materials, with their lightweight, high strength, corrosion resistance, and flexible processing, are widely used in aerospace, petrochemicals, automotive manufacturing, precision instruments, construction materials, electronics, glass products, and fitness equipment. These materials integrate multiple components, including carbon fiber, glass fiber, epoxy resin, and phenolic resin, overcoming the limitations of single materials. However, during raw material preparation, production processes (such as lamination, injection molding, curing), and finished product storage, flammable, explosive, or toxic gases may be present, including methane, propane, volatile hydrocarbons, benzene compounds (benzene, toluene, xylene), chlorine, ammonia, and hydrogen sulfide. Leaks can cause fires, explosions, poisoning, or environmental pollution, endangering worker health and business operations.

Industry standards such as GB/T 14441 and GB 50016 emphasize that high-risk areas must be equipped with gas monitoring systems to enable real-time detection and early warning. Nexisense provides single-gas to multi-gas online monitoring solutions for fiber composite environments, helping enterprises build safety barriers at raw material warehouses, workshops, and curing ovens to ensure production continuity and compliance.

Fiber Composite Gas Risk Analysis

• Raw material stage: Resins, curing agents, and solvents (e.g., benzene compounds, acetone) emit VOCs, causing dizziness, respiratory irritation, or chronic poisoning at high concentrations.

• Production processes: Lamination, molding, or winding at high temperatures releases hydrocarbons; chlorination may release Cl₂; amino resin curing generates NH₃.

• Storage and transport: Flammable gases accumulate in confined spaces, forming LEL mixtures; H₂S and other toxic gases corrode equipment and exacerbate leaks.

Effective monitoring intervenes before gas concentrations reach occupational exposure limits (PC-TWA/PC-STEL), activating ventilation or emergency evacuation, significantly reducing accident probability.

Selecting Gas Detection Equipment for Fiber Composites

• Target gas and range: Combustible gases 0-100% LEL; toxic gases like NH₃/Cl₂ 0-10ppm or 0-100ppm; multi-gas scenarios use 4-in-1 or multi-gas detectors.

• Sampling method: Diffusion for open workshops; pump or ducted sampling for pipelines or enclosed ovens.

• Performance: Response<30s, accuracy ±2%FS, temperature/humidity compensation; explosion-proof Ex d IIC T6 Gb, IP65+ protection.

• System compatibility: Supports 4-20mA/RS485 Modbus RTU for PLC/DCS integration.

• Manufacturer considerations: ISO9001 certified, fast after-sales support, and references to aerospace or petrochemical projects.

Nexisense Core Products

SGA-500 Series Fixed Online Gas Detector

Utilizes imported sensors with patented algorithms (32-bit microprocessor + 24-bit ADC full-range compensation), tested for high stability and low error.

• 24V power, plug-and-play, LCD real-time display, automatic alarm + relay output.

• Supports diffusion, pump, and duct sampling for combustible/toxic gases.

• Modular design with customizable range, sensors, alarm points, and units.

• Built-in intelligent calibration and lifespan reminder.

• Suitable for high-temperature, humid composite workshops.

Multi-Gas Monitoring System

SGA-500 multi-gas integrates sensors (e.g., combustible + NH₃ + Cl₂ + VOC) for multi-parameter monitoring. Combined with SGA-800 controller, enables centralized display, historical storage, and relay-linked control (220V/5A for fans/valves). Additional options include portable inspectors, online VOC monitoring, and emission monitoring for workshop and environmental compliance.

Installation Guidelines

• Heavy gases (benzene, H₂S): install 30-60cm below leak sources for accumulation capture.

• Light gases (NH₃, H₂): install near the top or 30-60cm below highest point.

• Horizontal distance: toxic gases ≤1m, combustible ≤7.5m.

• O₂/H₂: 30-60cm above/below or mid-level.

• Wiring: shielded 3/4-core cables; branch wiring for few points, bus wiring for expansion.

• Controller: choose 4/8/16 channels for unified alarm management.

Typical Applications

• Aerospace composites: VOC monitoring in epoxy resin lamination and curing, linked to oven ventilation.

• Petrochemical: fiber-reinforced pipe production, Cl₂/H₂S detection, corrosion leak prevention.

• Automotive/electronics: carbon fiber injection molding workshop, multi-gas detection (combustible + benzene compounds).

• Construction materials: glass fiber curing, NH₃/SO₂ real-time alert.

  
  

FAQ

1. Which gases are monitored and how to handle multi-gas scenarios?
SGA-500 covers combustible gases (0-100%LEL), benzene compounds (0-100ppm), VOCs (0-500ppm), Cl₂ (0-10/20ppm), NH₃ (0-100ppm), H₂S (0-50ppm). Single-gas devices for high-precision; multi-gas version integrates 4-6 sensors for complex resin curing environments.

2. Explosion-proof and protection rating?
Ex d IIC T6 Gb, IP65+, -40℃ to +70℃, resistant to humidity, resin dust, and solvents; suitable for aerospace clean lamination, automotive injection, petrochemical fiber-reinforced pipe production.

3. How to choose sampling methods?
Diffusion for open workshops; pump sampling for high-temperature ovens or closed molding chambers; ducted for resin pipelines or exhaust ducts. Pump can include heated lines and multi-stage filters for VOC/NH₃ sampling.

4. Sensor accuracy, lifespan, calibration, and drift mitigation?
±2%FS,<30s response. Electrochemical 2-3 yrs, catalytic/IR 3-5 yrs. Full-range temperature/humidity compensation, dual-point calibration every 12 months, drift diagnostics and lifespan prediction.

5. Installation considerations?
Heavy gases 30-60cm below sources, light gases at top or 30-60cm below, horizontal distance toxic ≤1m, combustible ≤7.5m. Avoid ventilation dead zones, resin splashes, shielded wiring, branch or bus configuration based on points, consider worker breathing zones.

6. Multi-level alarm, control, and PLC/DCS integration?
Three thresholds (pre-alarm/level 1/level 2), independent outputs: local ventilation, pump/heat cutoff, full workshop evacuation; 4-20mA/RS485 Modbus RTU for PLC/DCS integration.

7. Special configurations for high-temperature curing or resin VOCs?
High-temp sensors (up to 150℃), heated pump sampling, solvent-resistant housing, activated carbon prefilter, wireless modules for retrofitting.

8. How to get selection, installation, and technical documentation?
Submit process details, target gases, layout, number of points; response within 24h. Provides manuals, certificates, 3D installation references, case studies. Standard products 1-3 days, customized 5-10 days.

Conclusion: Nexisense Empowers Fiber Composite Safety

Production safety in fiber composites impacts innovation and sustainability. Nexisense provides high-precision sensors, flexible sampling, and reliable system integration for raw material handling and workshop monitoring, mitigating flammable, explosive, and toxic risks. Contact Nexisense for customized solutions, on-site assessment, and technical support. Efficient manufacturing starts with reliable monitoring.