RFID Sensor for Bioprocessing Component Status Monitoring
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Solution Overview
Problem
Single-use bioprocessing systems require manual verification of connections, which is time-consuming and prone to errors, potentially leading to contamination and leakage, as existing methods lack continuous monitoring capabilities.
Innovation Solution
Integration of sensors, such as RFID tags and wireless sensor nodes, to provide real-time status monitoring of components, allowing for automated verification and control of bioprocessing systems, including disposable components like tubing clamps and valves, through wireless communication with a control system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual verification of connections is used, then device complexity is reduced, but reliability deteriorates due to human error and lack of continuous monitoring
Solution Approach 1:
The system enables self-verification through automated sensor monitoring. Sensors attached to components automatically detect connection status, component presence, and operational parameters, eliminating the need for manual verification while maintaining system reliability through continuous self-monitoring.
Solution Approach 2:
Manual mechanical verification processes are replaced with electronic sensor-based detection systems. RFID tags, optical sensors, and wireless communication modules substitute for human visual inspection and manual checking, providing automated reliability verification without proportional increase in mechanical complexity.
2Reliability
If continuous monitoring is implemented, then reliability is improved, but loss of time for setup and operation increases
Solution Approach 1:
Sensors and RFID tags are pre-integrated into components during manufacturing. Connection interfaces include built-in detection elements that automatically activate upon assembly, eliminating the need for separate monitoring setup steps and reducing overall system configuration time while enabling continuous monitoring from the start of operation.
Solution Approach 2:
The monitoring system operates autonomously without requiring manual activation or configuration. Sensors automatically detect component presence and connection status upon assembly, and the control system continuously processes sensor data without user intervention, eliminating setup time for monitoring functions while maintaining continuous reliability oversight.
3Productivity
If manual connection verification is used, then ease of operation is maintained, but productivity deteriorates due to repeated checking and process delays
Solution Approach 1:
The system implements automatic feedback loops where sensors continuously monitor connection status and component operational parameters, and the control system receives real-time data to verify proper assembly and operation. This automated feedback eliminates repeated manual checking while maintaining operational simplicity through centralized control and automated decision-making.
Solution Approach 2:
Manual verification operations are replaced with automated electronic detection and control systems. Wireless communication modules and sensor arrays substitute for human inspection processes, enabling continuous monitoring that increases productivity without significantly complicating system operation through centralized control interfaces and automated alerting.
4Reliability
If sensors are integrated into disposable components, then reliability is improved through automated detection, but device complexity increases
Solution Approach 1:
The sensor modules are designed as universal, multi-functional units that can be attached to various component types (tubing, connectors, filters, pumps). Each sensor provides multiple detection capabilities (connection status, presence detection, operational parameters) through a single integrated device, reducing the need for multiple specialized components and minimizing overall system complexity while maximizing monitoring reliability.
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
Enables continuous, real-time monitoring and control of bioprocessing systems, reducing the risk of errors and contamination by providing immediate feedback on component status and position, thus enhancing process integrity and efficiency.
Implementation Method 1
a sensor including a first portion configured to provide an identifier; and a second portion configured to provide a status indication... The sensor can be any type of sensor, including, but not limited to, a radio frequency identification (RFID) tag
Data Source
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AI summary
Methods, systems, and apparatus to monitor component status in a bioprocessing environment are disclosed and described. Certain examples provide a sensor device for a disposable bioprocessing component. The example sensor device includes a first portion affixed to the component, the first portion configured to provide an identifier associated with the component. The example sensor device also includes a second portion configured to provide a status indication based on a state of the component. The example sensor device is configured to transmit the identifier and status indication to a control computer associated with a bioprocessing platform including the component.