Surge tank based system to control surge tanks for automated operation and control of continuous manufacturing train

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Solution Overview

Problem

Existing continuous manufacturing trains for monoclonal antibodies face challenges in controlling surge tanks, which are often implemented on a case-by-case basis without comprehensive guidelines, leading to operational complexities, increased costs, and difficulties in handling process deviations and product variability.

Innovation Solution

A surge tank based system with integrated data acquisition, normalization, deviation identification, and control engines, utilizing sensors and a centralized computer to manage surge tanks, enabling real-time control and deviation handling in continuous manufacturing trains.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If surge tanks are implemented in continuous manufacturing trains, then process flexibility and deviation handling capability are improved, but device complexity and operational complexity increase

Engineering Contradiction:

Improveprocess flexibilityVSAvoiddevice complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The control system is designed to perform multiple functions including data acquisition from multiple sensors, data normalization, deviation identification through statistical analysis, and automatic control execution. This multi-functional approach allows a single integrated system to handle various process parameters and deviation types without requiring separate specialized systems for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent introduces a centralized control system as an intermediary between the surge tanks and the manufacturing process. This intermediary collects data from multiple sources, processes it through normalization and statistical analysis, and executes control actions that coordinate multiple unit operations. The intermediary manages the complexity by centralizing control logic rather than distributing it across multiple independent systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If surge tanks are implemented in continuous manufacturing trains, then process flexibility and deviation handling capability are improved, but capital costs and operational costs increase

Engineering Contradiction:

Improveprocess flexibilityVSAvoidcapital costs

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The control system operates autonomously by automatically acquiring data from sensors, normalizing the data, identifying deviations through statistical analysis, and executing control actions without human intervention. This self-service capability reduces operational complexity and allows the system to manage surge tanks and coordinate unit operations independently, offsetting the initial capital investment through reduced manual operation requirements.

Inventive Principle:

Principle #25Self-service

3Reliability

If comprehensive control systems are implemented for surge tanks, then deviation handling capability is improved, but device complexity increases

Engineering Contradiction:

Improvedeviation handling capabilityVSAvoiddevice complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control system continuously monitors process parameters through sensors and uses statistical process control to compare actual values against expected ranges. When deviations are detected, the system automatically executes control actions and continues monitoring to verify correction. This closed-loop feedback mechanism improves reliability by ensuring deviations are detected and corrected systematically while managing complexity through automated decision-making algorithms.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual monitoring and control mechanisms with an automated electronic control system that uses statistical analysis and algorithms to identify deviations and execute control actions. This substitution of mechanical/manual processes with electronic automation improves deviation handling capability while managing complexity through software-based control logic rather than complex hardware interconnections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12522799B2Surge tank based system to control surge tanks for automated operation and control of continuous manufacturing train

Publication Date: 2026.01.13 INDIAN INSTITUTE OF TECHNOLOGY

AI summary

Described herein is a surge tank based system to control surge tanks in a manufacturing train. The system includes data acquisition unit, data normalization unit, deviation identification and handling unit and an real time execution of control action from centralized computer in a manufacturing process unit, wherein said manufacturing unit includes an integrated system which incorporates a plurality of pumps, surge tanks, and weighing balances, and other unit operations alongside the normal unit operations of production of output product.