Parallel Vessel Process Control With Dynamic Sampling Allocation
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Solution Overview
Problem
Current methods for determining a multivariate process chart to control chemical, pharmaceutical, biopharmaceutical, and biological product production are resource-intensive and inefficient, particularly when working with small-scale vessels, as they require significant sampling and labor, and often cannot integrate scientific instruments due to cost or size constraints.
Innovation Solution
A method using a first process control device to control and sample multiple first-scale vessels in parallel, with varying process parameters, periodic determination of process parameter values, and assigning vessels to analysis or excluded subsets to optimize sampling frequency and resource allocation, allowing for the creation of a multivariate process chart with minimal resources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods are used to determine a multivariate process chart, then the process control can be established, but the resource consumption and labor requirements increase significantly
Solution Approach 1:
The patent segments the vessel population into multiple subsets (e.g., first subset, second subset, third subset) that are monitored at different frequencies. This segmentation allows the system to allocate sampling resources differentially, with some vessels sampled frequently and others sampled less frequently, thereby reducing overall resource consumption while maintaining adequate process control reliability through the distributed monitoring approach.
2Measurement precision
If sampling frequency is increased to improve process monitoring, then measurement precision improves, but labor and resource costs increase
Solution Approach 1:
The patent implements dynamic sampling frequencies for different vessel subsets rather than using a uniform static sampling rate. The sampling frequency is adjusted based on the specific subset assignment, allowing the system to optimize the balance between measurement precision and sampling efficiency. This dynamic approach enables higher measurement precision for critical vessels while maintaining overall productivity through reduced sampling of less critical vessels.
3Measurement precision
If scientific instruments are integrated into small-scale vessels, then measurement capability improves, but device complexity and cost increase
Solution Approach 1:
The patent employs a centralized process control device that serves multiple functions: it controls process parameters, coordinates sampling operations, manages subset assignments, and processes data from multiple vessels. This universal control device eliminates the need for each small-scale vessel to have integrated scientific instruments, thereby reducing device complexity and cost while maintaining measurement capability through the centralized system's coordination of periodic sampling and analysis.
Data Source
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AI summary
Aspects of the application relate to computer-implemented methods, process control devices and a computer program. According to one aspect, a computer-implemented method for controlling a process in a plurality of first scale vessels via a first process control device is provided. Each of the first scale vessels contains fluid and the process is for producing a chemical, pharmaceutical, biopharmaceutical and/or biological product. The method comprises receiving, by the first process control device, process parameters, the process parameters including process parameters to be controlled and process parameters to be measured. The method further comprises controlling, by the first process control device and at least partly in parallel, the process in each of the first scale vessels. The method further comprises periodically determining, prior to an assigning decision and at a first frequency, first sets of process parameter values for each of the process parameters from each of the first scale vessels. The method further comprises carrying out the assigning decision by assigning corresponding ones of the first scale vessels to an analysis subset and other ones of the first scale vessels to an excluded subset. The method further comprises periodically determining, after the assigning decision and at a second frequency, second sets of process parameter values for each of the process parameters from the analysis subset of the first scale vessels. The first frequency is different from the second frequency. The method further comprises controlling, by the first process control device and at least partly in parallel, the process in the first scale vessels of the analysis subset according to the second sets of process parameter values.