Self-adaptive taper dynamic aeration two-way gas supply system and control method

Abstract

The invention relates to a self-adaptive taper dynamic aeration two-way gas supply system and a control method, belongs to the technical field of bioengineering and bioreactor equipment, and provides a two-way collaborative gas supply system adopting a sliding plug-in type self-adaptive aeration disc and a control method. The aeration disc can move on the inverted-cone-shaped inner wall, and the diameter of the aeration disc can be automatically adjusted to keep sealed attachment, so that accurate and dead-zone-free oxygen supply and multi-mode flow field regulation and control in a full-cone-surface range are realized, and the defects that in the prior art, a torrent bioreactor aeration device is fixed in position, cannot adapt to a cone-shaped variable-diameter structure and is single in oxygen supply mode are overcome.

Description

Technical Field

[0001] This invention relates to the field of bioengineering and bioreactor equipment technology, and in particular to an adaptive tapered dynamic aeration dual-path air supply system and control method. Background Technology

[0002] The production of biopharmaceuticals (such as antibodies, vaccines, and recombinant proteins) and cell therapy products (such as stem cells and CAR-T cells) heavily relies on the performance of bioreactors. Among them, turbulent flow bioreactors achieve fluid mixing through the periodic oscillation or rocking of the tank. Due to their advantages such as low shear force, mild mixing, and single-use, they are widely used in the shear-sensitive animal cell culture.

[0003] However, as cell culture processes develop towards higher density and higher titers, existing turbulent flow bioreactors have revealed significant bottlenecks in oxygen supply and mixing control:

[0004] Limitations of top aeration: Traditional turbulent flow reactors primarily rely on surface renewal between the gas and liquid surfaces in the headspace for mass transfer. During high-density cell culture, oxygen diffusion solely through the gas-liquid interface is insufficient to meet the rapidly increasing oxygen demand (OUR) of growing cells, leading to difficulties in maintaining dissolved oxygen (DO) levels and impacting cell growth and product expression.

[0005] Dead zones and shear resistance in stationary aeration devices: To supplement oxygen supply, existing technologies attempt to add microbubble aeration devices to the side walls or bottom of the tank. However, for the inverted conical structure commonly found in turbulent flow reactors, fixed-position aeration devices struggle to meet the needs of different culture stages. If placed at the bottom, while strong shear can break up the bubbles, it can damage delicate cells in the early stages; if placed at a higher position, mass transfer efficiency is insufficient when large flow volumes are required. Furthermore, fixed structures easily create localized dead zones in the inverted conical flow field, leading to uneven mixing.

[0006] The challenge of dynamic sealing on variable-diameter conical surfaces: To overcome the drawbacks of fixed positions, those skilled in the art have envisioned using movable aeration devices. However, the core characteristic of the inverted conical tank is that its inner diameter varies with height. Existing rigid annular aeration pipes cannot adapt to diameter changes; while conventional flexible pipes struggle to maintain a continuous and reliable seal on the variable-diameter surface during movement. If the seal is not tight, gas can easily escape along the wall (gas short-circuiting), failing to enter the main flow field, and may also cause mechanical jamming or scratches on disposable culture bags.

[0007] Therefore, there is an urgent need to develop an innovative aeration system that can not only move freely on the inverted conical inner wall, but also automatically adapt to changes in diameter and always maintain a tight fit and seal, and to cooperate with corresponding intelligent control strategies to achieve precise oxygen supply throughout the entire process cycle. Summary of the Invention

[0008] The primary objective of this invention is to overcome the shortcomings of existing technologies in turbulent bioreactors, such as fixed aeration devices, inability to adapt to conical variable-diameter structures, and a single oxygen supply mode. This invention provides a dual-path coordinated air supply system and control method employing a "sliding plug-in adaptive aeration disc." This aeration disc can move on the inverted conical inner wall and automatically adjust its diameter to maintain a tight seal, thereby achieving precise, dead-zone-free oxygen supply and multi-mode flow field control across the entire conical surface.

[0009] To achieve the above objectives, the present invention provides an adaptive tapered dynamic aeration dual-path air supply system, comprising:

[0010] The reactor body has an inverted conical cavity. The reactor body includes a rigid tank with an inverted conical cavity and a disposable culture bag placed inside it. After the disposable culture bag is filled with liquid, its bottom has the same inverted conical structure as the inverted conical cavity.

[0011] The top air intake subsystem is used to supply gas to the top space of the inverted conical cavity. The top air intake subsystem includes a first gas source, a first gas filter, and a top pressure regulating valve connected in sequence through pipelines.

[0012] Adaptive dynamic inverted cone aeration subsystem: This subsystem is the core of this invention and includes:

[0013] A slidable plug-in adaptive aeration disc is composed of a first semi-annular flexible tube and a second semi-annular flexible tube connected by a sliding plug-in joint. The outer diameter of the first semi-annular flexible tube is adapted to the inner diameter of the second semi-annular flexible tube, allowing them to slide relative to each other along the annular tangential direction. This changes the overall diameter of the slidable plug-in adaptive aeration disc to adapt to the cross-sectional diameter of the inverted conical cavity at different heights. In one embodiment, one end of the first semi-annular flexible tube has a male connector, and one end of the second semi-annular flexible tube has a female connector. The male connector is slidably inserted into the female connector, forming an annular structure with radial expansion and contraction freedom. Due to the different preset radii of curvature of the two semi-annular tubes, when the aeration disc moves in the inverted conical section, under the action of its own flexible restoring force, fluid pressure, and external driving force, the male connector slides along the tangential direction within the female connector, thereby changing the overall diameter of the combined ring so that it always matches the curvature of the conical surface at different heights, achieving a dynamic and tight fit. A dynamic sealing ring is fitted on the male connector to ensure airtightness throughout the sliding process.

[0014] Magnetic drive unit: The semi-annular flexible tube is doped with permanent magnet material powder or embedded with flexible magnetic strips, making it a controlled "mover".

[0015] Electromagnetic drive and positioning unit: includes an electromagnetic matrix integrated into the outer wall of the inverted conical part of the tank. The control unit adjusts the energizing sequence and current of the coil to generate a moving magnetic field traveling wave, which drives the aeration disc to move along the inverted conical wall in a non-contact manner.

[0016] Air supply unit: It is connected to the aeration disc through a flexible buffer pipeline and is equipped with a precision gas flow regulating valve.

[0017] Monitoring and control system: This includes sensors for dissolved oxygen, pH, pressure, oscillation frequency, etc., as well as control units. The control units are configured to execute a multi-mode coordinated control method with integrated dynamic position regulation.

[0018] The present invention also provides a control method based on the above system, comprising:

[0019] Real-time monitoring of dissolved oxygen concentration, cell density, and oscillation frequency within the culture bag;

[0020] Based on the collected data to determine the process stage, the aeration disc height (H) is dynamically switched between the following three modes and adjusted synchronously:

[0021] a) Basic / Mild Mode (High Position): During the initial stage of culture or when oxygen consumption is low, control the aeration disc to the high position (about 2 / 3 of the cone height), turn off or slightly turn on bottom aeration, and use top aeration and high-position mild circulation to protect sensitive cells.

[0022] b) Synergistic / Balanced Mode (Midpoint): During the exponential growth phase, control the aeration disc to the midpoint (approximately 1 / 2 cone height), start bottom aeration and adjust the flow rate using PID, and utilize the central flow field to balance mixing efficiency and shear force.

[0023] c) Enhanced / High-Efficiency Mode (Low Position): During high-density or extreme oxygen consumption periods, the aeration disc is controlled to a low position (approximately 1 / 3 of the cone height), significantly increasing the ventilation rate and oscillation frequency. The strong shear flow field at the bottom of the cone is used to break up the bubbles, achieving extreme mass transfer.

[0024] The system also has self-checking and self-tuning functions: before operation, it drives the aeration disc to move through its full stroke and judges the fit by monitoring the driving force curve; during operation, it finely adjusts the position based on energy consumption feedback to ensure optimal fit.

[0025] Compared with the prior art, the present invention has significant beneficial effects:

[0026] The innovative conical surface adaptive seal: Through the structural design of "sliding insertion + variable diameter semi-ring", it cleverly solves the problem of sealing and fitting when the flexible body moves on the variable diameter conical surface, eliminates "oxygen short circuit" and local dead zones, and significantly improves the uniformity of oxygen supply.

[0027] Fully sterile and non-contact driven: The built-in magnetic aeration disc is driven by an electromagnetic matrix, eliminating the need for mechanical motion interfaces on disposable culture bags and completely ensuring the sterility of the system.

[0028] Multidimensional synergistic precise regulation: By introducing "spatial location" as the core control variable into the oxygen supply strategy, a leapfrog performance of "high temperature and cell preservation, low oxygen supply" has been achieved, enabling a single reactor to simultaneously handle the culture tasks from extremely sensitive cells to high-density engineered cells.

[0029] Intelligent process management: By introducing feedforward control and position self-tuning algorithms, it can proactively predict oxygen demand trends and automatically optimize the hydrodynamic environment, significantly shortening the cultivation cycle and increasing product yield. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0031] Figure 1 This is a schematic diagram of the overall structure of the adaptive tapered dynamic aeration dual-path air supply system provided by the present invention.

[0032] Figure 2 This is an exploded view and a partially enlarged schematic diagram of the slidable plug-in adaptive aeration disc in this invention.

[0033] Figure 3 This is a flowchart of the multi-mode collaborative control method for integrated dynamic position control executed by the control unit of the present invention.

[0034] Figure 4 This is a simplified schematic diagram of another adaptive tapered dynamic aeration dual-path air supply system provided by the present invention.

[0035] Figure 5 This is a schematic diagram comparing the working states provided by the present invention.

[0036] Figure 6 This is a partial cross-sectional view of the drive and sealing provided by the present invention.

[0037] Figure label:

[0038] 1. Reactor body; 11. Inverted conical tank; 12. Disposable bioprocessing culture bag; 2. Top air inlet subsystem; 21. First air source; 22. First gas filter; 23. Top pressure regulating valve; 24. Piping; 3. Adaptive dynamic inverted conical aeration subsystem; 31. Aeration disc; 311. First semi-annular flexible tube; 312. Second semi-annular flexible tube; 313. Male connector; 314. Female connector; 315. Gas pipe plug; 316. Micropores; 32. Dynamic sealing ring; 33. Magnetic drive unit; 34. Electromagnetic drive and positioning unit; 35. Air supply unit; 351. Second air source; 352. Second gas filter; 353. Precision gas flow regulating valve; 354. Buffer pipeline; 36. Guide key; 4. Monitoring and control system; 41. Sensing unit; 42. Control unit. Detailed Implementation

[0039] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0040] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0041] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0042] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0043] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0044] It should be noted that when an element is referred to as being "fixed to" or "set on" another element, it can be directly on the other element or there may be an intervening element. When an element is considered to be "connected to" another element, it can be directly connected to the other element or there may be an intervening element. The terms "vertical," "horizontal," "upper," "lower," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only possible implementation.

[0045] Example 1: Structure of an Adaptive Conical Dynamic Aeration Dual-Path Air Supply System for a Turbulent Flow Bioreactor

[0046] like Figure 1 and Figure 4 As shown in the figure, the present invention provides an adaptive cone dynamic aeration dual-path air supply system for a turbulent bioreactor, which mainly includes a reactor body 1, a top air inlet subsystem 2, an adaptive dynamic inverted cone aeration subsystem 3, and a monitoring and control system 4.

[0047] 1. Reactor body

[0048] The reactor body has an inverted conical cavity, including an external rigid inverted conical tank 11 and a disposable bioprocessing culture bag 12 placed inside it. The culture bag is made of a flexible multilayer membrane material, and when it is placed inside the tank and filled with liquid, its lower part is constrained by the tank to form an inverted conical structure. This inverted conical design is beneficial for forming specific fluid vortices during turbulent oscillation, but it also causes the cross-sectional diameter to vary with height.

[0049] 2. Top intake subsystem

[0050] The top air intake subsystem 2 is used to maintain the top space pressure within the culture bag and provide surface mass transfer. It includes a first gas source 21 (typically air or an air / CO2 mixture), a first gas filter 22 (0.22 μm sterile filter), and a top pressure regulating valve 23, which are sequentially connected via conduit 24. The ends of the conduit are connected to a pre-fabricated interface at the top of the culture bag via heat-sealed or sterile connectors.

[0051] 3. Adaptive dynamic inverted cone aeration subsystem

[0052] This is the core component of the present invention, designed to solve the problems of variable diameter sealing and dynamic oxygen supply. Specifically, it includes:

[0053] Sliding plug-in adaptive aeration disc 31: such as Figure 2 As shown, the aeration disc 31 is annular and is composed of a first semi-annular flexible tube 311 and a second semi-annular flexible tube 312 connected by a sliding plug joint. One end of the first semi-annular flexible tube 311 has a male connector 313, and one end of the second semi-annular flexible tube 312 has a female connector 314. The male connector 313 can be slidably inserted into the female connector 314. The top surface of the female connector 314 also has an air pipe plug 315 for connecting to an external input pipe.

[0054] Taper adaptive mechanism: The outer diameter of the first semi-annular flexible tube 311 is slightly smaller than the inner diameter of the second semi-annular flexible tube 312 (or the radii of curvature of the two are designed with a preset micro-difference), allowing the male end to slide smoothly along the annular tangential direction within the female end. When the aeration disc 31 moves downward along the inner wall of the inverted conical tank (the diameter decreases), it is squeezed by the wall surface, causing the male end to slide deeper into the female end, shortening the overall circumference of the ring; conversely, when it moves upward, the circumference increases. This structure allows it to always match the curvature of the conical surface at different heights, achieving a dynamic and tight fit.

[0055] Dynamic sealing design: A dynamic sealing ring 32 (such as an O-ring or lip seal) is fitted on the male connector 313 to ensure that the air passages in the two halves of the annular tube remain connected and leak-free throughout the entire sliding and telescopic process. In addition, the end of the sliding plug-in connector is provided with a limiting protrusion or a snap-fit ​​structure to prevent the male connector from completely disengaging from the female connector at its extreme position.

[0056] Micropore design: The surface of the aeration disc 31 is provided with several laser-drilled micropores 316, which face the central axis of the tank and diagonally upwards, so as to facilitate the detachment of bubbles and their entry into the mainstream field.

[0057] Magnetic drive unit 33 ( Figure 6As shown in the diagram): To achieve non-contact actuation, permanent magnet material powder (such as neodymium iron boron powder) is uniformly incorporated into the wall material of the first semi-annular flexible tube 311 and the second semi-annular flexible tube 312, or flexible magnetic strips are embedded in the grooves on their outer walls. This makes the entire aeration disc 31 a "mover" that can be controlled by a magnetic field.

[0058] Electromagnetic drive and positioning unit 34: This unit is integrated into the outer wall of the inverted conical portion of the rigid inverted conical tank 11. It includes an electromagnetic matrix composed of multiple sets of electromagnetic coils arranged in a regular pattern (such as a three-phase linear motor arrangement). The control system generates an axially moving magnetic field wave inside the tank wall by precisely controlling the energizing sequence, phase, and current magnitude of each coil. This magnetic field penetrates the rigid tank wall and the flexible bag wall, attracting and driving the internal magnetic drive unit 33, thereby causing the aeration disc 31 to move up and down along the inverted conical wall. This unit also integrates a Hall sensor or a magnetostrictive displacement sensor as a position sensor for real-time feedback of the height information of the aeration disc 31.

[0059] The air supply unit 35 includes a second air source 351, a second gas filter 352, and a precision gas flow regulating valve 353 (such as a mass flow controller MFC). The end of the pipeline is connected to a long, flexible buffer pipeline 354 (spiral or serpentine), and the other end of the flexible buffer pipeline 354 is connected to the air inlet on the aeration disc 31 to accommodate the up-and-down movement of the aeration disc.

[0060] 4. Monitoring and Control System

[0061] Sensing unit 41 includes a dissolved oxygen (DO) sensor (optical patch type or electrode type) inserted into the culture bag, a pH sensor, a pressure sensor for monitoring the pressure inside the bag, an acceleration sensor or encoder for monitoring the oscillation frequency of the tank, and the aforementioned position sensor.

[0062] Control unit 42: Uses a PLC or industrial PC. Its signal input terminal is connected to the sensing unit 41, and its output terminal controls the top pressure regulating valve, the precision gas flow regulating valve, the electromagnetic drive and positioning unit 34, and the main motor that drives the tank to oscillate.

[0063] Example 2: Multi-mode cooperative control method integrating dynamic position regulation

[0064] This embodiment describes the control process for cell culture using the above-described device, such as... Figure 3 As shown.

[0065] Step 1: Sterilization and Installation

[0066] During the production phase, the manufacturer pre-installs the adaptive aeration disc 31 inside a disposable culture bag and connects it to the flexible buffer piping. The entire assembly is sterilized by gamma ray. When using the device, the user places the culture bag into the tank of the reactor body 1, ensuring the bag adheres to the wall, and then connects the external piping.

[0067] Step 2: System initialization and bonding self-test

[0068] Before or immediately after injecting the culture medium, the control unit 42 executes a "self-test procedure":

[0069] The electromagnetic drive and positioning unit 34 generates an upward magnetic field, which drives the aeration disc 31 to move from the bottom of the cone (about 1 / 5 of the height) to the top of the cone (about 4 / 5 of the height).

[0070] During this process, the control unit 42 monitors the current value of the drive coil in real time (reflecting the driving force). If the current curve is smooth and within the preset threshold, it indicates that the aeration disc 31 can extend and retract freely with the taper and fits well with the bag wall; if the current suddenly increases abnormally at a certain point, it indicates that there may be bag wall wrinkles or foreign objects stuck, and the system will alarm.

[0071] Step 3: Dynamic multi-mode control during operation

[0072] After the culture begins, the control unit 42 collects dissolved oxygen (DO), cell density (based on online turbidity or offline sampling input), oscillation frequency, and aeration disc height (H) in real time. Based on these parameters, the system automatically switches between the following three modes:

[0073] Mode A: Basal / Mild Mode (Early Culture Stage, Low Density, High DO)

[0074] Triggering conditions: DO > target upper limit (e.g., 60%), low cell density.

[0075] Position action: The control unit 42 drives the aeration disc 31 to move and lock it in the high position (H≈2 / 3 cone height). At this time, the diameter of the aeration disc is larger.

[0076] Airflow strategy: Top intake subsystem 2 is open, maintaining a slight positive pressure. Air supply unit 35 (bottom) is closed or only a small amount of gas is introduced to prevent micropore blockage.

[0077] Effects: Avoids bottom bubble shear damage to sensitive cells, and utilizes top mass transfer to meet low oxygen demand.

[0078] Mode B: Synergistic / Balanced Mode (Exponential Growth Phase, DO Decline)

[0079] Triggering condition: DO enters the target range (e.g., 40%-60%) and shows a downward trend.

[0080] Positioning action: Control unit 42 drives aeration disc 31 to move down to the middle position (H≈1 / 2 cone height). During the downward movement, the male head slides into the female head, and the diameter of aeration disc 31 automatically contracts to maintain a seal.

[0081] Gas supply strategy: Start gas supply unit 35 and use PID algorithm to adjust bottom flow based on DO deviation.

[0082] Effect: By utilizing the flow field characteristics in the middle of the tank, the efficiency of bubble breaking and shear force are balanced to achieve efficient mixing.

[0083] Mode C: Enhanced / High-Efficiency Mode (High-Density Period, DO Critical)

[0084] Triggering conditions: DO < target lower limit (e.g., 40%), or extremely high cell density.

[0085] Position action: The control unit 42 quickly drives the aeration disc 31 to move down to the low position (H≈1 / 3 cone height). At this time, the aeration disc 31 retracts to its minimum diameter and is in close contact with the bottom of the cone.

[0086] Gas path and oscillation strategy: The gas supply unit 35 significantly increases the gas volume (superimposed with feedforward control), while the control unit 42 instructs the motor to increase the tank oscillation frequency.

[0087] Effect: By utilizing the strongest shear flow field at the bottom of the cone, the bubbles are broken down into micron-sized particles, greatly increasing the gas-liquid contact area and achieving ultimate oxygen supply.

[0088] Step 4: Position-Taper Self-Tuning

[0089] After each positional movement, the control unit 42 executes a fine-tuning algorithm: it slightly shakes the aeration disc 31 up and down near the target height to find the point with the minimum driving current. This point represents the optimal mechanical balance between the tension of the aeration disc and the supporting force of the pipe wall, i.e., the optimal fit point, thereby compensating for minor errors caused by manufacturing tolerances or differences in bag installation.

[0090] Through the above-described embodiments, the present invention successfully resolves the contradiction between oxygen supply bottleneck and shear force control in traditional turbulent bioreactors. By combining "adaptive deformation" in hardware with "position-flow field coupling control" in software, the invention achieves intelligent and efficient cell culture processes.

[0091] Example 3

[0092] This embodiment illustrates another structural schematic diagram of the device. See also... Figure 4 This embodiment illustrates the overall physical architecture of the system. The inverted conical tank of reactor body 1 (marked 1 in the figure) is a rigid support structure, and disposable culture bags (marked 2 in the figure) are tightly attached inside it. Figure 1 The core feature of this system—"non-contact drive layout"—is clearly demonstrated:

[0093] External drive: Electromagnetic drive and positioning unit 34 (corresponding to) Figure 6 The magnetic drive unit 33 is not a single point, but rather a group of electromagnetic matrix arrays arranged in layers along the inverted conical generatrix direction of the outer wall of the tank. This array design allows the control unit to generate a continuously moving magnetic field gradient.

[0094] Built-in response: The adaptive aeration disc 31 is suspended inside the culture bag. Figure 1 It is shown that it is connected to the top via a flexible buffer pipe (marked 6 in the figure), which is designed with sufficient margin (such as a spiral or S-shaped bend) to accommodate the up and down movement of the aeration disc 31 throughout the entire cone height, ensuring continuous air supply without positional limitations.

[0095] Sensing feedback: The dissolved oxygen sensor (one type of sensing unit 41) is placed in the active flow field area at the bottom or side wall and is connected in a closed loop with the external control unit 42 to form a feedback loop.

[0096] Example 4

[0097] Regarding the mechanical structure of the adaptive aeration disc:

[0098] See Figure 2 The exploded view reveals in detail the internal structure of the "sliding plug-in adaptive aeration disc," which is key to achieving variable diameter sealing:

[0099] The aeration disc body is composed of a first semi-annular flexible tube 311 and a second semi-annular flexible tube 312. Crucially, the two are not simply joined together, but rather connected via a male connector 313 and a female connector 314. The outer diameter of the male connector 313 is precision machined to match the inner diameter of the female connector 314.

[0100] Anti-rotation guide: To prevent the two half-rings from twisting relative to each other in a turbulent oscillating environment, thus preventing overall warping, the male end has a raised guide key 36 (or guide bar) on its surface, and the female end has a corresponding guide groove on its inner wall. This design restricts the degrees of freedom, allowing the two half-rings to only extend and retract along the circumferential tangential direction.

[0101] Dynamic sealing: Figure 2 The enlarged view shows the dynamic sealing ring 32 (such as a fluororubber O-ring) embedded in the groove of the male connector 313. When the male connector slides in the female connector, the dynamic sealing ring 32 always presses against the inner wall of the female connector, forming a dynamic sealing interface to prevent gas leakage from the connection and ensure that gas can only be ejected from the preset micro-holes 316.

[0102] Micropore orientation: Micropores 316 are distributed along the tube body, and their opening direction is designed to face obliquely upward and towards the central axis. This not only facilitates the convergence of bubbles towards the center under the carrying force of the fluid, but also utilizes the backflow force of the airflow to help the aeration disc adhere tightly to the cone wall.

[0103] Example 5

[0104] The working principle of variable diameter adaptive (combined with...) Figure 5 ):

[0105] See Figure 5 The figure visually compares the morphological changes of the aeration disc at different heights within the inverted conical container, confirming its "adaptive" capability:

[0106] High position (H1): When the aeration disc is located in the wider area (H1) at the top of the tank, the two semi-rings slide outward relative to each other due to the reduced constraint of the tank wall and the elasticity of the material itself (or the internal spring element). The male head is pulled out more from the female head, so that the overall circumference of the aeration disc is maximized (as shown by the dotted line in the figure) to fit the large diameter cross section.

[0107] Low position (H2): When the electromagnetic force drives the aeration disc to move down to the narrower bottom area (H2), the conical sidewall generates a radial compressive force on the aeration disc. This force forces the two semi-rings to overcome the friction of the sealing ring and slide inward relative to each other, with the male head penetrating into the female head, causing the overall circumference of the aeration disc to shrink (as shown by the solid line in the figure) to tightly fit the small diameter section.

[0108] Full-range fit: Throughout the entire movement from H1 to H2, the aeration disc acts like a variable-diameter "aperture" structure, always maintaining a zero-gap or micro-gap fit with the inverted conical inner wall, completely eliminating the fluid dead zone of traditional fixed rings in variable-diameter containers.

[0109] Example 6

[0110] Details regarding non-contact actuation and sealing (in combination) Figure 6 ):

[0111] See Figure 6 This partial cross-sectional view explains the mechanism of driving force transmission and airtightness from a microscopic perspective:

[0112] Through-wall driving path: The magnetic lines of force generated by the energized electromagnetic coil (electromagnetic drive and positioning unit 34) (shown as dashed lines in the figure) penetrate the rigid tank wall (marked 11 in the figure) and the flexible disposable culture bag membrane (marked 12 in the figure) in sequence. Since both of these materials are non-magnetic (such as stainless steel or plastic), the magnetic field can act on the permanent magnet embedded in the aeration coil wall without damage.

[0113] Magnet layout: The permanent magnet (magnetic drive unit 33) is encapsulated inside the outer wall of the outer tube of the aeration disc (i.e., the female head connection part 314), closely attached to the bag membrane, so as to shorten the magnetic air gap and maximize the coupling force.

[0114] Sliding airtight interface: The dynamic sealing ring 32 is located between the male connector 313 and the female connector 314, confining the high-pressure gas inside the pipeline. Even when the aeration disc moves up and down due to magnetic traction and radial compression deformation occurs externally, this sealing structure can still maintain airtightness through the elastic deformation of the O-ring, demonstrating the precise structural engineering design of this invention.

[0115] This embodiment illustrates how the system makes trade-off decisions between professional matching and load balancing, achieving intelligent allocation that takes into account both professional matching and workload balancing.

[0116] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0117] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. An adaptive cone-shaped dynamic aeration dual-path air supply system, characterized in that, include: The reactor body has an inverted conical cavity; A top air intake subsystem is used to supply gas to the top space of the inverted conical cavity; An adaptive dynamic inverted cone aeration subsystem includes a slidable pluggable adaptive aeration disc disposed inside the inverted cone cavity, and an electromagnetic drive and positioning unit disposed on the outer wall of the inverted cone cavity. The slidable plug-in adaptive aeration disc is composed of a first semi-annular flexible tube and a second semi-annular flexible tube connected by a sliding plug joint, forming an annular structure with radial expansion and contraction freedom. The outer diameter of the first semi-annular flexible tube is adapted to the inner diameter of the second semi-annular flexible tube, so that the two can slide relative to each other along the annular tangential direction, thereby changing the overall diameter of the slidable plug-in adaptive aeration disc to adapt to the cross-sectional diameter of the inverted conical cavity at different heights. The electromagnetic drive and positioning unit includes an electromagnetic matrix arranged on the outer wall of the inverted conical cavity, which drives the slidable plug-in adaptive aeration disc to move up and down along the inner wall of the inverted conical cavity in a non-contact manner by generating a magnetic field. The monitoring and control system includes a sensing unit and a control unit. The control unit coordinates the control of the top air intake subsystem, the adaptive dynamic inverted cone aeration subsystem, and the electromagnetic drive and positioning unit based on the feedback signal from the sensing unit.

2. The adaptive tapered dynamic aeration dual-path air supply system according to claim 1, characterized in that, The sliding connector includes a male connector at one end of the first semi-annular flexible tube and a female connector at one end of the second semi-annular flexible tube; a dynamic sealing ring is fitted on the male connector to maintain air passage sealing during sliding. The sliding connector is also provided with a limiting structure to prevent the male connector from completely disengaging from the female connector. The female connector has a guide groove inside, and the male connector has a guide key on the outside to prevent the two semi-annular flexible tubes from rotating relative to each other.

3. The adaptive tapered dynamic aeration dual-path air supply system according to claim 1, characterized in that, The first and second semi-annular flexible tubes have permanent magnet material powder uniformly incorporated into their tube wall material, or flexible magnetic strips embedded in their outer wall, so that they can respond to the magnetic field traveling wave generated by the electromagnetic drive and positioning unit. The adaptive aeration disc has several micro-holes on its tube body, and the opening direction of the micro-holes is towards the central axis of the inverted conical cavity and obliquely upward.

4. The adaptive tapered dynamic aeration dual-path air supply system according to claim 1, characterized in that, The adaptive dynamic inverted cone aeration subsystem also includes an air supply unit, which includes an air source, a precision gas flow regulating valve and a flexible buffer pipeline connected in sequence. One end of the flexible buffer pipeline is connected to the air inlet of the adaptive aeration disc and is used to transfer gas as the aeration disc moves.

5. A control method for the adaptive tapered dynamic aeration dual-path air supply system according to any one of claims 1 to 4, characterized in that, The control unit executes a multi-mode collaborative control strategy with integrated dynamic position adjustment, including the following steps: S1: Real-time acquisition of dissolved oxygen concentration, cell density signal, tank oscillation frequency, and real-time height of the adaptive aeration disc inside the disposable culture bag installed in the inverted conical cavity; S2: Compare the collected dissolved oxygen concentration value with the preset target range, and combine it with the cell density signal to determine the current culture process stage; S3: Based on the judgment result of step S2, switch between the basic mild mode, the coordinated balance mode and the enhanced high efficiency mode, and simultaneously control the electromagnetic drive and positioning unit to drive the adaptive aeration disc to the corresponding height area, while adjusting the air supply flow rate and the tank oscillation frequency.

6. The control method according to claim 5, characterized in that, The mode switching in step S3 specifically includes: a) Basic Mild Mode: When in the early stage of cultivation or when the dissolved oxygen concentration is in the high range of the target range, the top air intake subsystem is turned on, the adaptive aeration disc is moved to the high range, and the adaptive dynamic inverted cone aeration subsystem is turned off or made to operate at the lowest flow rate. b) Collaborative Balance Mode: When cells enter the exponential growth phase or the dissolved oxygen concentration is in the median range of the target range, the adaptive dynamic inverted cone aeration subsystem is activated and the flow rate is adjusted based on the PID algorithm, while the adaptive aeration disc is controlled to move to the median region. c) Enhanced high-efficiency mode: When in the high-density cultivation stage or when the dissolved oxygen concentration is in the low range of the target range, feedforward control is used to increase the air volume of the adaptive dynamic inverted cone aeration subsystem, increase the tank oscillation frequency, and control the adaptive aeration disc to move to the low-level area.

7. The control method according to claim 5, characterized in that, It also includes system initialization and bonding self-test steps: Before cultivation begins, the control unit drives the adaptive aeration disc to move its full range from the bottom to the top of the inverted cone structure. The electromagnetic force or current parameters required to drive the adaptive aeration disc are monitored in real time and compared with the preset normal force-position curve. If the monitored parameters exceed the preset threshold at a certain position, it is determined that there is an abnormal fit or foreign object interference at that position, and an alarm is issued. If all parameters are normal, the system self-test is considered to have passed.

8. The control method according to claim 5, characterized in that, It also includes a position-taper self-tuning step: During the process of controlling the adaptive aeration disc to move to the target height, the control unit fine-tunes the final stopping position based on the real-time feedback of drive energy consumption data, and takes the position corresponding to the minimum drive energy consumption as the optimal fitting position. And / or, Based on the current tank oscillation frequency, the pre-stored optimization database is queried, and the adaptive aeration disc is automatically adjusted to the optimal bubble dispersion height corresponding to that frequency.

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