Bioreactor Failure Recovery via Data Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cell culture bioreactor systems face challenges in recovering from failures, particularly in small-scale cultures where unique cell batches respond differently to environmental parameter changes, leading to loss of control and potential irrecoverable cell loss.
Innovation Solution
Implementing a communication device for data exchange between bioreactor systems, using wireless protocols like IEEE 802 standards, and a non-volatile memory to store and transfer culture process data, allowing seamless transfer of a disposable cell bag to a backup system for continued culture without reprogramming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predetermined routine is used for small scale cell culture, then large scale commercial cell culture can be efficiently managed, but small batches of unique cell batches cannot adapt to their specific characteristics and respond differently to parameter changes
Solution Approach 1:
The system dynamically switches between operating modes: using predetermined routines for large scale commercial cell culture to maintain efficiency, and transitioning to feedback-driven iterative control for small batches of unique cell batches to adapt to their specific characteristics. This dynamic adaptation resolves the contradiction between productivity and adaptability.
Solution Approach 2:
The system changes its control parameters and strategies based on the scale and uniqueness of the cell batch. For small batches, it employs iterative parameter adjustments based on real-time feedback, while for large scale commercial batches, it uses fixed predetermined parameter routines, thus adapting to different operational requirements.
2Extent of automation
If system failure occurs in small scale cell culture, then control parameters are lost and the system must re-learn adjustments, but this causes deviation in parameters and potential cell loss
Solution Approach 1:
The system performs preliminary actions by continuously recording and storing control parameters, process data, and environmental conditions during normal operation. This preliminary data collection ensures that when system failure occurs, the data is already captured and can be used to quickly restore control without re-learning, thus maintaining reliability during failures.
Solution Approach 2:
The system uses feedback mechanisms to continuously monitor environmental parameters and control device status. When failure is detected through feedback signals, the system retrieves previously recorded data and resumes control, maintaining reliability while preserving the automated control framework.
3Reliability
If real-time recording of control parameters and process data is implemented, then rapid recovery from failure is enabled, but device complexity increases
Solution Approach 1:
The system creates copies of control parameters and process data in real-time and stores them in memory. This copying mechanism enables rapid recovery from failures without requiring complex real-time computation during recovery, thus improving reliability while keeping the added complexity manageable through simple data duplication and storage.
Data Source
Figure 1a
Figure 1b
Figure 2a~2c
AI summary
Disclosed is a cell culture system comprising a first cell culture bioreactor system (10) for culturing cells to a predetermined cell density or quantity, the system including a bioreactor volume (20), a process controller (30), process control devices (32) which provide inputs (16) for the culture volume and culture parameter measurement devices (14), wherein the process controller is operable according to plural control program steps to control the process devices to provide inputs for a suitable cell culture environment in the bioreactor volume, and is further operable according to control program steps modified by feedback values from the culture parameter measurement devices, and comprises a memory (36) operable to record data indicative of the progress of the control program steps. Failure of the system can be rectified by moving the bioreactor volume to another similar system which has access to data indicative of any incomplete program steps which steps may have been modified by feedback from the measurement devices.