Machine Learning-Enhanced NDIR Methane Sensing Solution for Robust Outdoor Continuous Monitoring Applications

This work presents the development of a low-cost and high-performance multi-sensory gas detection instrument named the AIMNet Sensor, with the integration of a machine learning-based data processing method. The compact and low-power instrument (8.5 × 11.5 cm, 1.4 W) houses the core sensing hardware module, Senseair K96, that integrates both a non-dispersive infrared (NDIR)-based gas sensing unit and a BME280 environmental sensing unit. To address the outdoor operation challenges caused by environmental fluctuation due to the varying temperature, humidity, and pressure, from the software aspect, multiple machine learning-based regression models were trained in this work on 13,125 calibration data points collected under controlled laboratory conditions. Among ten tested algorithms, the Multilayer Perceptron (MLP) and Elastic Net models achieved the highest accuracy, with R-squared coefficient R2>0.8 on both indoor and outdoor scenarios, and with inter-sensor root mean square error (RMSE) within 1.5 ppm across four identical instruments. Moreover, field mobile validation was performed near a wastewater management facility using this solution, confirming a strong correlation with LI-COR reference measurements and a reliable detection of CH4 leaks with concentrations up to 18 ppm at the test site. Overall, this machine learning-integrated NDIR sensing solution (i.e., AIMNet) offers a practical and scalable solution towards a more robust distributed CH4 monitoring network for real-world field-deployable applications.