Industrial Firefighting Robot Dog: Hazard Site Suppression

I. Project Background

    A heavy machinery plant, spanning an area of 450,000 square meters, contains core production workshops—such as forging, welding, and heat treatment—that are exposed to multiple fire hazards including extreme heat, flammability, and explosion risks. Furnaces in the forging workshop operate at up to 1200°C, with flammable materials like heavy oil and waste oil stored nearby. The welding workshop carries the risk of stray sparks igniting surrounding combustible debris such as wood chips and cardboard. The heat treatment workshop utilizes quenching oil, which is prone to ignition at high temperatures.

    Previously, the plant relied on a "manual inspection and fixed fire suppression systems" model, which had several critical shortcomings:

1. The harsh workshop environment—characterized by high temperatures, dust, and noise—led to inspector fatigue and a missed hazard detection rate of 18%. In 2023, a small fire in the welding workshop, caused by sparks igniting debris, was not detected promptly, resulting in minor equipment damage.

2. Fixed fire suppression systems had limited coverage, leaving areas like corners and spaces beneath large equipment unprotected.

3. After a fire ignition, it was dangerous and difficult for personnel to quickly approach high-temperature equipment to assess the situation, often leading to delayed or imprecise firefighting response.

    To enhance its fire prevention and control capabilities, the plant deployed five industrial firefighting robotic dogs in March 2024.

II. Implementation Process

1. Adaptation and Deployment (March 8 – March 23)

    The technical team made specialized modifications to the robotic dogs for industrial environments:

• They were equipped with an infrared thermal imager (temperature range: -20°C to 1500°C) and a spark recognition camera to accurately identify fire precursors such as abnormal heat and stray sparks.

• A dry powder fire extinguishing cartridge launcher (effective range: 10 meters, suitable for oil and solid fuel fires) and an audible/visual alarm module were installed.

• The units were built with a heat-resistant and impact-resistant shell, enabling continuous operation in ambient temperatures up to 60°C and offering protection against minor impacts.

• Integrated with digital workshop layouts, a 3D fire safety map was created using LiDAR scans, detailing large equipment, firefighting assets, and storage points for hazardous materials.

• Five pre-defined patrol routes were established for key areas (e.g., Forging Workshop, Welding Workshop). Alert thresholds were configured, including for high-temperature warnings (surface temperature exceeding rated levels by 10%) and spark detection (spark diameter ≥ 3mm). Full integration with the plant's fire alarm system was completed.

2. Trial Operation and Optimization (March 24 – April 12)

A 20-day trial was conducted in the core workshops using a "robotic patrol with safety officer verification" model. Three daily patrols were performed (morning, afternoon, night shift), each lasting 2 hours. Key improvements during this phase included:

• Reducing False Alarms: Algorithms were refined to better distinguish welding sparks from other light sources, lowering the false alarm rate from 20% to 2%.

• Enhancing Maneuverability: Limb structures were optimized, allowing the dogs to navigate through gaps as narrow as 0.4 meters between large machines.
  Post-trial testing confirmed a 99% accuracy rate in identifying fire hazards, with an alert response time of one minute or less.

3. Formal Operation (April 13 – Present)

    The five firefighting robotic dogs are now permanently stationed in their assigned workshops, providing 24/7 automated patrols. During normal operations, they follow their pre-set routes, continuously monitoring for hazards like abnormal heat and sparks. Upon detecting a potential fire risk, they immediately activate on-site alarms and transmit the location and visual data to the fire control room. In the event of a small fire, they can autonomously deploy dry powder extinguishers for initial suppression while simultaneously guiding human firefighters to the exact location.

III. Application Results

• Improved Hazard Detection: The rate of missed fire hazards dropped from 18% to 0%. In 2024, the system identified 23 instances of abnormal high temperature and 15 spark hazards, all of which were addressed promptly. The detection rate for incipient fires increased from 40% to 98%, with three such fires being successfully contained.

• Enhanced Response Efficiency: The average response time to a fire hazard alert was reduced from 10 minutes to 1 minute. The time to contain an incipient fire decreased from 30 minutes to 5 minutes. The average financial loss per fire incident fell from approximately 500,000 RMB to below 50,000 RMB.

• Optimized Operations and Safety: Six manual fire patrol positions were eliminated, resulting in annual labor cost savings of about 900,000 RMB. By replacing human workers in high-temperature, dusty, and hazardous environments, the robotic dogs have significantly reduced physical strain and improved operational safety.

IV. Typical Scenarios

Scenario 1 (Prevention - August 20, 2024): During an afternoon patrol in the forging workshop, a robotic dog's thermal imager detected the surface temperature of a heavy oil storage drum near a furnace had risen to 75°C, exceeding its 60°C safety rating. The system instantly issued a high-temperature alert, sending the drum's location and temperature data to the control room. A safety officer dispatched to the scene discovered the drum was too close to the furnace and had developed a minor leak. While the robotic dog continued to monitor the site, the officer safely relocated the drum and repaired the leak. This early intervention prevented a potential spontaneous combustion event, averting estimated losses of 800,000 RMB.

Scenario 2 (Rapid Suppression - September 5, 2024): In the welding workshop, sparks from a workstation ignited wood chips on the floor. A nearby robotic dog immediately detected the flames, triggered an alarm, and launched a dry powder extinguishing cartridge. The initial fire was suppressed within 30 seconds, preventing any damage to equipment or injury to personnel.