Intelligent Gateway Routing for Bioprocess Controller Data Priority
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Solution Overview
Problem
Conventional bioprocessing control systems face limitations in processing power, inefficient data transmission, and inability to distinguish between high-priority and low-priority data, leading to processing bottlenecks and increased operational costs due to direct communication between bioprocessing instruments and the control system without proper data prioritization.
Innovation Solution
An intelligent gateway system that prioritizes and optimizes data transmission by separating primary and secondary data sets, using a unique communication protocol address for primary data and a single address for secondary data, reducing the computational load on the bioprocess controller and enabling efficient handling of a larger and more diverse set of data from multiple bioprocessing instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If all bioprocessing instrument data is transmitted through the controller to the main control system, then complete data collection is achieved, but the controller processing load increases and creates bottlenecks
Solution Approach 1:
The patent segments data into two categories: primary data (process-critical parameters like temperature, pH, dissolved oxygen) and secondary data (instrument status and configuration information). The intelligent gateway transmits only primary data through the controller to the main control system, while secondary data is handled locally or transmitted separately. This segmentation reduces the controller's processing load while maintaining complete data collection for process control decisions.
2Adaptability or versatility
If multiple bioprocessing instruments are connected directly to the control system, then instrument connectivity is maximized, but network resources and processing capacity are overwhelmed
Solution Approach 1:
The patent introduces an intelligent gateway as an intermediary device between bioprocessing instruments and the main control system. The gateway aggregates data from multiple instruments and performs intelligent routing: primary process data is forwarded to the controller, while secondary instrument data is managed locally. This intermediary architecture enables multiple instruments to connect without proportionally increasing network resource consumption or controller processing capacity.
3Reliability
If the controller processes all data from all instruments, then comprehensive control is achieved, but operational delays increase
Solution Approach 1:
The patent applies local quality by enabling the intelligent gateway to perform local data processing and filtering. The gateway identifies and prioritizes primary process data that requires immediate controller attention, while secondary instrument data is processed locally or deferred. This local quality approach ensures comprehensive control of critical process parameters while reducing operational delays by filtering out non-critical data before it reaches the controller.
4Ease of operation
If standard communication protocols are used for all data transmission, then protocol compatibility is maintained, but data prioritization and efficient transmission are prevented
Solution Approach 1:
The patent changes data transmission parameters by implementing different transmission strategies for primary and secondary data. Primary process data is transmitted with higher priority, more frequent updates, and direct routing to the controller. Secondary instrument data uses lower priority, less frequent transmission, and local handling where possible. These parameter changes maintain protocol compatibility while dramatically improving data transmission efficiency and enabling intelligent data prioritization.
Data Source
AI summary
A bioprocessing control system can include an intelligent gateway. The gateway can receive, from a controller, a request for data associated with the plurality of bioprocessing instruments including a primary data set and a secondary data set. The primary data set includes a block of primary data measured by the plurality of bioprocessing instruments. The secondary data set has a lower priority than the primary data set. The gateway can cause the controller to control the bioprocessing instrument by at least: sending, to the controller in response to the request, the block of primary data. The gateway can send, to the controller during the sending the block of primary data and in response to the request, a portion of the secondary data set, thereby reducing a load on the controller.