Hybrid Sensor Network for Autoclave Stopper Displacement Control
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Solution Overview
Problem
Current autoclaving techniques for pre-filled vials, such as pre-filled syringes, are expensive, time-consuming, and prone to inaccuracies due to sensor reliability and repeatability issues in harsh autoclave conditions, leading to potential compromise of vial contents.
Innovation Solution
A hybrid sensor network combining physical and virtual sensors, utilizing a proportional-integral-derivative (PID) controller block, simulates stopper displacement to maintain vial integrity by compensating for friction under varying autoclave conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical sensors are deployed in autoclave chambers to monitor sterilization conditions, then measurement capability is provided, but sensor reliability and repeatability deteriorate due to harsh high-temperature and high-pressure conditions
Solution Approach 1:
The patent creates a virtual copy of the physical sensor system through digital simulation. Virtual sensors are implemented in software to replicate the measurement functions of physical sensors, allowing monitoring of autoclave conditions without exposing fragile measurement equipment to harsh environments. This digital twin approach maintains measurement capability while eliminating the reliability issues of physical sensors in high-temperature, high-pressure conditions.
Solution Approach 2:
The patent replaces the mechanical/physical sensor system with a computational/digital system. Instead of using physical devices that degrade under autoclave conditions, the system uses virtual sensors implemented through software simulations that can accurately track temperature, pressure, and other parameters without being subject to the same degradation mechanisms as physical hardware.
2Reliability
If traditional autoclaving techniques are used for pre-filled vials, then sterilization is achieved, but the process becomes expensive and time-consuming with potential compromise of vial contents
Solution Approach 1:
The patent applies preliminary action by using virtual sensors and digital simulations to predict and optimize autoclave processes before actual sterilization. The system simulates various autoclaving scenarios to determine optimal parameters that ensure vial contents integrity, thereby preventing potential compromise of contents before it occurs and reducing the need for costly reprocessing or validation experiments.
Solution Approach 2:
The patent implements feedback mechanisms through virtual sensing that continuously monitors simulated autoclave conditions and adjusts process parameters in real-time. This closed-loop control ensures that sterilization conditions remain within optimal ranges to protect vial contents, while the digital nature of the feedback system allows for rapid adjustments without the delays associated with physical sensor response times.
3Productivity
If physical sensors operate in hostile autoclave conditions, then real-time monitoring is provided, but measurement accuracy deteriorates due to tolerance variation limitations
Solution Approach 1:
The patent creates virtual copies of the monitoring system that operate in the digital domain rather than the physical domain. These virtual sensors provide real-time monitoring capability by simulating sensor responses based on process model equations, eliminating tolerance variation limitations that affect physical sensors while maintaining the ability to monitor autoclave conditions in real-time.
Data Source
AI summary
Method and system of packaging a pre-filled vial. The method includes simulating, in a processor of a computing system based at least in part on a simulation model that includes a proportional-integral-derivative (PID) controller block, a frictional disengaging of a stopper that is engaged with the pre-filled vial responsive to progressively varying physical conditions within an autoclave chamber, the PID controller block receiving sensor data of the progressively varying physical conditions based on a hybrid sensor network that includes at least one physical sensor and at least one virtual sensor, the pre-filled vial containing a gaseous portion that is separated from air contained within the autoclave chamber by the stopper. Generating, by the processor based on the progressively varying physical conditions, a measure corresponding to a stopper displacement in accordance with the frictional disengaging, and packaging the pre-filled vial based at least in part on the generated stopper placement.