Bioreactor Sensor Control Using Virtual Transmitters
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Solution Overview
Problem
Bioprocess control systems for bioreactors are costly and complex, with redundant components like digital transmitters increasing costs and limiting accessibility to smaller biotech organizations, and existing systems lack intuitive user interfaces and full diagnostic access to sensor data.
Innovation Solution
Implementing a software-based 'virtual' transmitter system that mimics the functionality of physical transmitters using electronic cards and digital bus communications, eliminating the need for separate transmitter hardware and providing a unified, intuitive user interface through the HMI, allowing for hot-swappable sensors and reduced validation requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical transmitters and dedicated hardware components are used in bioreactor control systems, then measurement and control functions are achieved, but system cost and complexity increase significantly
Solution Approach 1:
The patent merges the transmitter functionality directly into the sensor element, eliminating separate transmitter hardware. The sensor element now performs both sensing and signal transmission functions, reducing the number of discrete components and simplifying the overall system architecture while maintaining reliable measurement and control functions
Solution Approach 2:
The sensor element is designed to be universal and multi-functional, serving as both the sensing element and the transmitter. This multi-functionality allows the same component to perform multiple roles (detection and signal transmission), reducing system complexity and component count while maintaining full measurement and control capabilities
2Loss of information
If physical transmitters with dedicated interfaces are used, then sensor data transmission is achieved, but user accessibility and ease of operation are reduced
Solution Approach 1:
The HMI interface is merged with the controller to create a unified user interface system. This integration allows users to access sensor data and system controls through a single intuitive interface, eliminating the need to interact with separate transmitter devices and improving overall user accessibility
Solution Approach 2:
The controller acts as an intermediary between the sensor elements and the user interface. It receives data from multiple sensors, processes the information, and presents it through the HMI in a user-friendly format, making sensor data accessible and understandable to users without requiring direct interaction with individual sensor transmitters
3Measurement precision
If multiple dedicated transmitter units are deployed, then comprehensive sensor monitoring is achieved, but hardware costs and system accessibility increase
Solution Approach 1:
The system is segmented into independent sensor elements that can be individually selected and configured based on specific monitoring needs. Each sensor element maintains full measurement precision for its specific function while the overall system avoids the cost of comprehensive transmitter units for each sensor type
Solution Approach 2:
The controller is designed as a universal platform capable of interfacing with multiple types of sensor elements through standardized communication protocols. This universality allows comprehensive sensor monitoring across different parameters (pH, dissolved oxygen, temperature, etc.) without requiring dedicated transmitter hardware for each sensor type, thereby reducing hardware costs while maintaining measurement precision
4Loss of information
If physical transmitter hardware is used, then sensor signal transmission is achieved, but adaptability and flexibility for configuration changes are limited
Solution Approach 1:
The patent replaces physical mechanical transmitter hardware with software-based signal processing and communication within the controller. This substitution allows configuration changes to be made through software programming rather than physical hardware modifications, significantly improving adaptability and flexibility while maintaining signal transmission integrity through digital communication protocols
Data Source
AI summary
A process and/or a bioreactor control system for controlling a bioreactor. The bioreactor control system includes a bioreactor, a sensor, an electronic card, and a bioreactor controller. The sensor is proximate to the bioreactor and configured to generate a signal indicative of an operating condition of the bioreactor. The signal is then transmitted to the electronic card. Receiving the signal, the electronic card processes the signal to generate a converted signal. The converted signal is then transmitted to the bioreactor controller. The bioreactor controller, in turn, processes the converted signal and generates a control signal to modify the operating condition of the bioreactor.