DE202025107201U1 - Real-time gas leak detection and automated response system - Google Patents

Abstract

A gas safety system consisting of a gas sensor module near a gas cylinder and a gas appliance, a smart shut-off valve at a gas outlet, an exhaust system to vent escaping gas, a disconnect relay at the building's power supply, and a control unit to estimate the leak rate. This control unit activates the valve as soon as the leak rate exceeds a first threshold, and the exhaust system, and cuts off the power supply as soon as the leak rate exceeds a second threshold. It also sends warning messages to a user device.

Description

Application area of the invention

The invention relates to gas safety systems for liquefied gas/natural gas installations that integrate leak detection, automatic shutdown, exhaust air routing, electrical isolation and user warnings to prevent escalation and improve responsiveness.

Background of the invention

Gas leaks in homes and industrial settings can pose fire and explosion hazards. Common safety measures include sensors with alarm functions, shut-off valves, and power disconnection to eliminate ignition sources. Studies and implementations demonstrate systems with semiconductor gas sensors (e.g., the MQ series), controllers, relays, GSM/IoT modules, and solenoid or electromechanical safety valves. These valves shut off supply lines, activate exhaust fans, and notify users, often with threshold values close to a fraction of the lower explosive limit (LEL). Standards and manufacturer recommendations specify detector placement based on gas density and typical alarm levels close to 10% LEL. They also require the integration of safety shut-off valves and compliance with electrical safety regulations. There remains a need for an integrated system that coordinates tiered responses based on leak rate and combines smart valves, exhaust and power disconnection with reliable notifications.

Summary of the invention

The invention relates to a system comprising a gas sensor array located near a gas cylinder and a device, a smart gas valve at the cylinder outlet, an exhaust system for forced ventilation, a disconnect relay for switching off the main circuit or selected circuits, and a control unit with graduated threshold values. If the estimated leak rate or concentration exceeds a first threshold value, the control unit actuates the smart valve to stop the gas flow. If a second, higher threshold value is exceeded, the control unit additionally opens the exhaust system and interrupts the power supply to prevent ignition hazards, and simultaneously sends warning messages to the users' end devices.

In some configurations, the system estimates the leak rate based on concentration increase dynamics and/or flow sensor data, applies hysteresis to prevent vibrations, verifies valve closure via position feedback, and restores normal operation after a gap is detected and manually confirmed. Notifications are sent via GSM/IoT to user apps and emergency contacts.

Detailed description

The sensor module includes one or more gas detectors for liquefied petroleum gas (LPG) and natural gas (e.g., semiconductor, catalyst, or NDIR detectors), positioned according to the gas distribution (LPG near the floor, methane near the ceiling) and calibrated to trigger an alarm at defined lower explosive limits (LEL). Optional temperature and pressure sensors improve leak rate determination. A control unit acquires the sensor data, applies filters, calculates a leak rate indicator, and compares it to two threshold values to trigger graduated actions.

An intelligent inline shut-off valve on the cylinder or in the supply pipe is electrically actuated and requires manual reset after activation. Safety-certified electromechanical valves with a quick-closing function are preferred; the control system actuates the valve via a protected relay and confirms the closing process using an integrated position switch.

A suction device that flushes the leakage area is controlled by the controller and is interlocked to prevent operation in the event of detected sparks or electrical faults; a timed ventilation cycle prevents overloading. A disconnect relay (or contactor) interrupts the main power supply or specific circuits as soon as the second threshold is exceeded to minimize ignition sources. The safety logic prioritizes shutdown over switching.

The alarm module uses GSM/SMS, push notifications, or voice calls to inform users and, optionally, service providers. The system logs events with timestamps, sensor trends, actions taken, and valve status for diagnostic purposes. A local HMI provides status LEDs, a buzzer, and a manual confirmation/reset button; for a reset, the gas level must fall below a safe threshold.

The installation instructions cover detector placement, regular calibration, valve maintenance, and functional testing. A backup power supply ensures the sensors and valves continue to function during power outages. Cybersecurity for IoT functions includes authentication. Decorative updates and encrypted data transmission.

During operation, the system monitors the ambient gas concentration. As soon as a concentration increase indicates a leak above the first threshold, the valve closes and a warning is issued. If the second threshold is reached, the system additionally opens the exhaust vent and interrupts the power supply, maintaining ventilation until the concentrations decrease. After safe conditions are reached and manual confirmation is given, the normal gas supply is restored.

Claims (4)

A gas safety system consisting of a gas sensor module near a gas cylinder and a gas appliance, a smart shut-off valve at a gas outlet, an exhaust system to vent escaping gas, a disconnect relay at the building's power supply, and a control unit to estimate the leak rate. This control unit activates the valve as soon as the leak rate exceeds a first threshold, and the exhaust system, and cuts off the power supply as soon as the leak rate exceeds a second threshold. It also sends warning messages to a user device. System according to Claim 1 , whereby the control system verifies valve closure via position feedback, applies hysteresis to threshold values, and requires manual confirmation before gas flow is restored after safe values have been reached. System according to Claim 1 , wherein the sensor module includes detectors calibrated to trigger an alarm at a fraction of the lower explosive limit and whose position is based on the gas density, and further includes temperature or pressure sensors to refine the leakage rate estimation. System according to Claim 1 , wherein the alerting module includes a GSM or IoT communication interface configured to send SMS or push notifications and to log events with timestamps and actions taken for diagnostic purposes.