Low-Cost Portable Sensor Node for Gas and Chemical Leak Detection with Kalman-Filtering-Based UWB Localization

The work environment in automated laboratories and industrial sites exposes workers to the risks associated with chemical gas and vapor leaks caused by unforeseen incidents. Such leaks may result in severe health hazards as well as damage to equipment or infrastructure at the leak site. Therefore, the development of systems capable of early detection and highly accurate localization of chemical leaks is of high importance for occupational safety. In this work, a low-cost, portable sensor node based on the Internet of Things (IoT) is proposed for the detection and localization of gas and chemical leaks in indoor environments. The sensor node features a modular design that enables flexible integration and replacement of gas and environmental sensors depending on the target application. In addition, the system includes an ultra-wideband (UWB)-based positioning and tracking unit, allowing operation across multiple indoor zones. The main contribution of this work lies in the combined integration of (i) multi-sensor-based environmental event detection and prediction and (ii) high-precision location within a dynamic multi-zone tracking architecture. The system automatically selects the most relevant anchors in each zone and applies trilateration and least-squares estimation, enhanced by Kalman filtering techniques. In particular, an extended Kalman filter (EKF) and an unscented Kalman filter (UKF) are employed, with sensor fusion incorporating inertial measurement unit (IMU) data to mitigate the effects of on-line-of-sight (NLoS) conditions and signal degradation caused by obstacles. Experimental results demonstrate that both the EKF and UKF significantly reduce positioning errors and improve tracking stability compared to baseline methods under challenging indoor conditions. The UKF shows superior performance in highly nonlinear scenarios. A quantitative evaluation using manually surveyed reference points showed that the UKF achieved the best overall performance, with a mean error of 39.72 cm and an RMSE of 43.03 cm. These findings confirm the effectiveness of Kalman filter-based sensor fusion for reliable indoor positioning and highlight the suitability of the proposed system for real-time safety monitoring applications.