Foam Sensor System for Bioreactor Foam Control
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Solution Overview
Problem
Bioreactors face frequent shutdowns due to foam buildup, leading to costly losses and production delays, as existing anti-foaming agents require continuous monitoring and often result in excessive use and downstream removal challenges.
Innovation Solution
A foam sensor system with a nickel-titanium alloy or copper-aluminum-nickel alloy transition member, connected to a foam contact and base, automatically detects foam levels and dispenses anti-foaming agents as needed, minimizing foam buildup and optimizing agent usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If anti-foaming agents are added continuously to control foam buildup, then foam levels are maintained, but excessive agent is used and downstream removal becomes difficult
Solution Approach 1:
The foam sensor detects foam buildup early and triggers anti-foaming agent dispensing before excessive foam reaches the exhaust filter. This preliminary detection and response prevents the need for continuous agent addition, allowing agent to be added only when necessary to maintain foam control while minimizing accumulation in the culture
Solution Approach 2:
The foam sensor provides continuous feedback on foam levels to the control system, which automatically adjusts anti-foaming agent dispensing. This closed-loop feedback ensures agent is added only when foam exceeds acceptable levels, maintaining reliable foam control while preventing excessive agent usage and accumulation that would require downstream removal
2Ease of operation
If large quantities of anti-foaming agent are added at set time intervals, then foam control is maintained without monitoring, but more agent than needed is used
Solution Approach 1:
The foam sensor provides real-time feedback on actual foam conditions, enabling the control system to dispense anti-foaming agent based on actual need rather than fixed schedules. This eliminates the need for continuous manual monitoring while preventing excessive agent addition that occurs with time-based dosing
Solution Approach 2:
The foam sensor and control system create a self-regulating system that automatically monitors foam levels and adjusts agent dispensing without operator intervention. The system serves itself by detecting when agent is needed and triggering dispensing, eliminating both manual monitoring and excessive scheduled addition
3Reliability
If anti-foaming agent is used to prevent foaming-out, then filter clogging is prevented, but downstream removal becomes more difficult and time-consuming
Solution Approach 1:
The foam sensor detects foam buildup early and triggers agent dispensing before foam reaches the exhaust filter, preventing filter clogging. By intervening early rather than allowing excessive foam accumulation, the system prevents the need for extensive downstream removal operations, maintaining both filter protection and downstream processing efficiency
Solution Approach 2:
The sensor provides continuous feedback on foam levels near the exhaust, enabling precise control of anti-foaming agent addition. This feedback-controlled approach prevents filter clogging by maintaining foam below critical levels while minimizing agent usage, thereby avoiding the downstream removal challenges that arise from excessive agent accumulation
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
The system continuously monitors and controls foam levels, preventing filter clogging and reducing anti-foaming agent usage, thereby minimizing losses and simplifying downstream processing.
Implementation Method 1
a transition member extending between the base and the foam contact with at least a portion of the transition member being openly exposed within the compartment of the container, at least a portion of the transition member having a second diameter that is smaller than the first diameter
Implementation Method 2
The transition member can be bent over an angle of at least 180° without plastic deformation
Data Source
AI summary
A foam sensor system includes a container bounding a compartment. A foam sensor assembly is mounted on the container and includes: a base being secured to the container; a foam contact being spaced apart from the base and disposed within the compartment of the container, at least a portion of the foam contact having a first diameter; and a transition member extending between the base and the foam contact with at least a portion of the transition member being openly exposed within the compartment of the container, at least a portion of the transition member having a second diameter that is smaller than the first diameter, the foam contact and transition member being connected together so that an electrical signal can pass therethrough.