Floating Foam Sensor Using Motion Data for Bioreactor Control
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Solution Overview
Problem
Conventional in-situ probes fail to effectively monitor foam levels in bioreactors due to their inability to compensate for dynamic fluid and foam level changes, leading to issues like filter clogging and reactor rupture, while excessive anti-foam addition can disrupt chemical processes.
Innovation Solution
A foam sensor device using accelerometers in a water-tight housing that floats on the liquid, analyzing movement data with machine learning to detect foam levels and automatically add anti-foam solution as needed, powered by a kinetic charger or inductive power receiver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional in-situ probes are used to monitor foam levels, then foam monitoring is attempted, but the probes fail to compensate for dynamic fluid and foam level changes, leading to measurement inaccuracies
Solution Approach 1:
The patent introduces an intermediary floating sensor platform that decouples the measurement system from the vessel bottom, allowing the sensor to move with fluid level changes. This floating intermediary carries the measurement equipment while adapting to dynamic conditions, resolving the contradiction between measurement precision and adaptability to fluid level changes.
Solution Approach 2:
The sensor system transitions from a static probe fixed at the vessel bottom to a dynamic floating platform that moves with the fluid surface. This dynamic adaptation allows continuous contact with the foam-liquid interface regardless of level changes, maintaining measurement accuracy while accommodating system dynamics.
2Object-affected harmful factors
If anti-foam solution is added to mitigate foam build-up, then foam control is improved, but excessive anti-foam solution disrupts chemical and biological processes
Solution Approach 1:
The patent implements a feedback control system where the floating sensor continuously monitors foam level and transmits data to a controller. The controller automatically adjusts anti-foam solution dosing based on real-time foam conditions, adding solution only when thresholds are exceeded. This closed-loop feedback minimizes anti-foam usage while maintaining effective foam control, preventing process disruption.
3Adaptability or versatility
If a floating sensor device is used to accommodate dynamic conditions, then adaptability to fluid level changes is improved, but device complexity increases due to water-tight housing and power systems
Solution Approach 1:
The patent employs a disposable or easily replaceable floating sensor unit with integrated water-tight housing and power system. Rather than designing for long-term durability with complex sealing and power management, the system uses simpler, lower-cost components that can be replaced periodically, reducing the complexity requirements while maintaining adaptability.
Solution Approach 2:
The floating sensor device incorporates self-contained power systems (batteries or kinetic chargers) and water-tight sealing that require no external maintenance or complex support infrastructure. The device autonomously operates in the dynamic environment, eliminating the need for complex external power transmission or sealing mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively monitors foam levels in bioreactors, preventing reactor issues and optimizing anti-foam use, ensuring continuous operation without disrupting the process.
Implementation Method 1
Movement of a sensor device within the vessel is detected via an accelerometer, and movement data is generated based on the detected movement
Implementation Method 2
the foam sensor device also includes a parasitic power device, such as kinetic charger, for charging the battery from the movement of the sensor device
Implementation Method 3
the device includes an inductive power receiver for receiving power transmitted inductively
Data Source
AI summary
A foam sensor device is used for monitoring foam within a vessel. The sensor (e.g. accelerometer) is encapsulated inside a water-tight, sterilizable, shell, which floats on a liquid contained. In one example, the foam sensor device includes an accelerometer for detecting and measuring rotation and movement of the foam sensor device and generates movement data based on the detected movement. During a learning or calibration process, sensor data (e.g., movement data) from the foam sensor device is analyzed and classified using machine learning and/or signal processing methods to extract features indicative of different possible foam statuses, including varying levels of foam, or no foam and generate models for the different statuses. During normal operation, the foam sensor device transmits sensor data to an analyzer containing the pre-calibrated models, which determines whether there is foam or not. Based on the foam status, a pump controller adds anti-foam solution.