Industrial Robot Gas Detection Solution: Nexisense SGA-700 Series Enhances Safety and Efficiency

Nexisense SGA-700 Series intelligent gas sensor modules are specifically developed for industrial robots, AGVs, and inspection robots. They support real-time monitoring of carbon monoxide, hydrogen sulfide, ammonia, sulfur dioxide, oxygen, sulfur hexafluoride, combustible gases, and more. The module features compact size, lightweight structure, standardized pins and outputs (0-5V / 4-20mA / TTL / RS485 / RS232 / USB), factory calibration with no on-site recalibration required, and true plug-and-play integration. Successfully deployed in leading AGV systems such as Yijiahe and Huawei, the SGA-700 significantly enhances industrial gas safety inspection and risk early-warning capabilities.

Industrial automation is rapidly evolving toward mobility and intelligence. AGV material handling robots, rail-mounted inspection robots, quadruped robots, and other equipment have been widely deployed in chemical parks, power substations, metallurgical plants, battery production lines, warehousing logistics centers, and more. While improving operational efficiency, these systems must also address safety challenges posed by toxic, harmful, and combustible gas leaks.

Fixed gas detectors have limited coverage and cannot follow dynamic robot paths, while manual inspections involve delays and exposure risks. The optimal approach is to integrate highly reliable gas sensors directly into the robot body, enabling mobile, real-time, full-coverage monitoring. Once abnormal concentrations are detected, robots can immediately trigger alarms, stop movement, adjust routes, or upload data—forming a complete closed loop from sensing to response. This has become a critical component of modern industrial safety systems.

Nexisense focuses on core gas sensing technologies. The SGA-700 Series intelligent gas sensor module is specifically optimized for robotic integration scenarios and has been stably operating in projects of multiple leading robot manufacturers, gaining strong market validation.

Practical Needs and Value of Integrating Gas Detection in Industrial Robots

Different industries face distinct gas risks:

• Chemical and pharmaceutical: ammonia, hydrogen chloride, hydrogen cyanide, nitrogen dioxide, and other corrosive/toxic gases;

• Power and substations: sulfur hexafluoride (SF6) and its decomposition products (e.g., SO2, H2S);

• Metallurgy, coking, battery manufacturing: accumulation of carbon monoxide and combustible gases (methane, hydrogen, etc.);

• Wastewater treatment and waste transfer: hydrogen sulfide, methane, and other odorous toxic gases;

• Confined space operations: oxygen deficiency and ozone overexposure.

Traditional monitoring methods can no longer meet the dual demands of continuity and safety in reduced-manning and unmanned production environments. Robots equipped with gas sensing modules can continuously scan along preset or autonomous routes. Detection data is bound to positional information, generating high-resolution gas distribution maps. This not only reduces abnormal response time to seconds but also provides reliable data for hazard tracing, process optimization, and emergency planning.

Practical applications show that robot systems equipped with mobile gas monitoring can reduce average gas-related incident handling time by more than 70%, while decreasing personnel entry into hazardous areas and improving overall equipment utilization and production continuity.

Core Design and Advantages of the Nexisense SGA-700 Series

The SGA-700 Series adopts original imported sensor cores (electrochemical, catalytic combustion, infrared principles, etc.). Through secondary calibration, real-time temperature and humidity compensation, signal amplification, anti-interference circuit optimization, and miniaturized packaging, Nexisense delivers a highly standardized intelligent module.

Standardized Design Greatly Reduces Integration Barriers

• All supported gas modules (CO, H2S, NH3, SO2, NO2, O3, HCl, HCN, O2, LEL, SF6, etc.) share identical dimensions, mounting holes, and pin definitions;

• Unified sampling method (diffusion type as standard, optional micro-pump for pump-suction mode);

• Robot mechanical structure and electrical interfaces do not require frequent redesign due to gas type changes, significantly shortening development cycles.

Flexible and Reliable Output Interfaces

• 5V supply version: 0-5V analog output + TTL serial port;

• 24V industrial supply version: 4-20mA current loop + TTL serial port;

• Optional expansion board supporting RS485 Modbus-RTU, RS232, USB-to-TTL, and other common industrial protocols;

• Output signals processed with digital filtering and long-term stability compensation, suitable for long-distance transmission and embedded acquisition systems.

This true plug-and-play capability enables robot developers to integrate the module like a standard sensor without complex driver development or on-site calibration.

Industrial-Grade Environmental Adaptability

• Operating temperature range: -20°C to +60°C (wider ranges available for certain gases);

• Built-in temperature and humidity compensation algorithms to offset environmental fluctuations;

• Low power consumption design compatible with battery-powered mobile robots for extended operation;

• Passed EMC, vibration, shock, and other industrial tests to meet harsh on-site conditions.

Typical Application Scenarios and Market Validation

• Lithium battery / new energy material AGVs: monitor combustible gases and carbon monoxide; automatically stop and alarm upon abnormal detection to prevent fire spread;

• Substation / switchgear inspection robots: detect SF6 leaks and decomposition products; generate leak heat maps with positioning for precise maintenance;

• Chemical pipeline / storage tank inspection robots: simultaneously monitor multiple toxic gases for 24-hour uninterrupted coverage, reducing high-risk manual work;

• Warehouse logistics robots: monitor oxygen deficiency or ozone levels to ensure confined space safety.

Multiple well-known robot brands have incorporated the SGA-700 Series into their standard selection or recommendation lists. Project feedback demonstrates stable performance and high customer recognition for ease of integration and long-term reliability.

Frequently Asked Questions (FAQ)

Q1: What gases does the SGA-700 Series support? Can it be customized?
A1: The standard series covers common industrial gases including CO, H2S, NH3, SO2, NO2, O3, HCl, HCN, O2, combustible gases (LEL such as methane and hydrogen), SF6 and some decomposition products. Custom development is available based on application scenario, concentration range, and environmental conditions.

Q2: Is on-site calibration required after factory calibration?
A2: All modules are factory-calibrated with temperature and humidity compensation parameters written in, enabling direct use without on-site calibration under standard conditions. For long-term reliability, periodic verification every 6–12 months is recommended depending on environmental exposure.

Q3: How to adapt to different robot power systems (12V, 48V, etc.)?
A3: Native support for 5V and 24V versions covers most systems. For other voltages, external DC-DC regulators (preferably isolated modules) can be used. Typical power consumption is below 100mW.

Q4: How to interface with different robot controllers?
A4: RS485 Modbus-RTU is recommended for industrial environments. TTL UART and 4-20mA/0-5V outputs are also available. Development resources including protocol documentation and sample code (STM32, Raspberry Pi, ROS) are provided.

Q5: Performance in high humidity, extreme temperatures, or dusty environments?
A5: Operating range is -20°C to +60°C and 0–95%RH (non-condensing). Protective membranes, dust filters, or IP54+ enclosures are recommended for harsh environments.

Q6: How to manage multiple modules on one robot?
A6: Use RS485 bus networking with Modbus addressing (up to 32–64 nodes depending on configuration). Supports centralized polling and synchronized data acquisition.

Q7: What affects electrochemical sensor lifespan?
A7: Extreme humidity changes, electrolyte consumption, cross-gas exposure, and prolonged high concentrations. Typical lifespan is 2–5 years depending on gas type and environment.

Q8: How to obtain technical documentation and samples?
A8: Visit the Nexisense official website for manuals and selection guides, or contact the technical support team with your application details for tailored recommendations and sample requests.

Conclusion

Gas detection has become a key enabling technology for industrial robots transitioning from mobility to intelligent safety. The Nexisense SGA-700 Series provides standardized design, stable outputs, wide gas coverage, and industrial-grade reliability, delivering efficient and cost-effective gas sensing solutions for robot manufacturers and end users.

Whether deploying new unmanned production lines or upgrading existing AGVs and inspection robots, integrating the SGA-700 significantly enhances on-site safety, reduces operational risks, and provides solid data foundations for digitalized maintenance. As multi-sensor fusion and edge intelligence continue to evolve, gas monitoring will integrate with broader environmental sensing to build comprehensive industrial digital twins. Nexisense remains committed to core technology innovation and collaborative industry advancement toward safer and more efficient industrial operations.