Integrated bio-reactor monitor and control system

• US 7,635,586 B2
• Filed: 02/10/2005
• Issued: 12/22/2009
• Est. Priority Date: 11/26/2003
• Status: Active Grant

• Current Assignee: New England Controls, Inc. (Enerpac Tool Group Corp.)
• Original Assignee: Broadley James Corporation
• Inventors: West, Larry Eugene
• Primary Examiner(s): Beisner; William H
• Assistant Examiner(s): HENKEL, DANIELLE B
• Application Number:
  US11/057,079
• Publication Number:
  US 20050158701A1
• Time in Patent Office: 1,776 Days
• Field of Search: 435/286.1, 435/289.1, 435/3, 700/266
• US Class Current: 435/286.1
• CPC Class Codes: C12M 41/48 Automatic or computerized control automatic analysis G01N35/00
• CPC Class Codes: C12Q 3/00 Condition responsive control processes apparatus therefor C12M1/36; controlling or regulating in general G05
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G05D 21/02 characterised by the use of electric means

Abstract

Systems and methods for automatically controlling conditions of a process are disclosed. In one example, a controller is programmed with a sequence of steps and parameters required to carry out a bioreactor process. A sensor system interacts with the bioreactor to receive information related to a condition of the bioreactor and/or receive a sample from the bioreactor, which it analyzes. The sensor system sends data signals related to the information and/or the sample to a controller, which determines a control signal based on the received information. The controller sends the control signal to the sensor system which, based on the control signal, performs an action that affects a condition of the bioreactor or affects the sensor system itself.

Claims

1. A system for controlling a process in a bioreactor, comprising:

a first sensor system comprising

a first sensor device, and

a first connection for communicating a material or information between said first sensor device and the bioreactor, wherein said first sensor device interacts with the bioreactor through said connection and wherein said first sensor device generates one or more data signals based on the material or information communicated from the bioreactor;

a control system for controlling the process in the bioreactor, said control system configured to communicate one or more control signals to said first sensor system wherein the control signals are based on data signals received from said first sensor system; and

a communication network connecting said control system and said first sensor system,

wherein said control system comprises

a controller configured with a bioreactor control process to control the conditions in a bioreactor by determining control signals based on the bioreactor control process and information received related to a condition in the bioreactor, and further configured to send the control signals over said communication network, and

a utility tower, housed separately from the bioreactor and coupled to said controller via said communication network, said utility tower configured to receive the control signals from said controller and to change a condition in the bioreactor based on the control signals, said utility tower comprising

a monitoring system that transmits information related to a condition of the bioreactor to said controller via said communication network, and

a bioreactor supply system which supplies a gas or liquid substance to the bioreactor in response to a control signal received from said controller,

wherein said first sensor system is configured to provide the one or more data signals related to a condition in the bioreactor to said control system using said communication network, and said first sensor system is further configured to receive one or more control signals from said control system and to perform a first action based on the one or more control signals.

2. The system of claim 1, wherein the material communicated to said first sensor device via the connection comprises a sample from the bioreactor for analysis by said first sensor system.

3. The system of claim 1, wherein said control system comprises:

a communication device connected to said first sensor system by said communication network, said communication device configured to receive the one or more data signals from said first sensor system, and said communication device further configured to send the one or more control signals to said first sensor system,

wherein said controller is connected to said communication device, said controller being also configured to analyze the one or more data signals to determine if the one or more data signals fall within a predetermined range of values, and said controller is further configured to generate the one or more control signals based on the analysis of the one or more data signals and communicate the one or more control signals to said communication device.

4. The system of claim 1, wherein the first action comprises sending one or more data signals related to the condition in the bioreactor to said control system.

5. The system of claim 1, wherein said communication network connecting said first sensor system and said control system is bi-directional.

6. The system of claim 1, wherein the condition comprises temperature.

7. The system of claim 1, wherein the condition comprises concentration of glucose.

8. The system of claim 1, wherein the condition comprises pH.

9. The system of claim 1, wherein the condition comprises concentration of dissolved oxygen (DO).

10. The system of claim 1, wherein the condition comprises an optical density of a substance in the bioreactor.

11. The system of claim 1, wherein the condition comprises concentration of dissolved carbon dioxide.

12. The system of claim 1, wherein said control system comprises a first computer connected to said control system and said first sensor system, said first computer configured to receive one or more data signals from said first sensor system, and said computer is further configured to provide one or more data signals to said controller.

13. The system of claim 2, wherein the first action affects one or more data signals subsequently sent to said control system by said first sensor system.

14. The system of claim 3, wherein said control system comprises a computer that comprises said communication device.

15. The system of claim 1, wherein the first action comprises a calibration process.

16. The system of claim 1, wherein the first action comprises a diagnostic process.

17. The system of claim 1, wherein the first action comprises performing an action to the bioreactor.

18. The system of claim 1, wherein the first action comprises changing a duty cycle for communicating data signals from said first sensor system to said control system.

19. The system of claim 12, further comprising:

a second sensor system, comprising

a second sensor device, and

a second connection for communicating a material or information between said second sensor device and the bioreactor, wherein the second sensor device interacts with the bioreactor through said second connection; and

a second computer connected to said second sensor system, said second computer configured to receive one or more data signals related to a condition in the bioreactor from the second sensor system, and said second computer is further configured to provide one or more data signals to said control system.

20. The system of claim 1, wherein said utility tower further comprises a data display touchscreen.

21. The system of claim 12, wherein said first computer is located outside of said utility tower.

22. The system of claim 19, wherein said second computer is connected to said first computer.

23. The system of claim 22, wherein said second computer provides one or more data signals to said control system via said first computer.

28. The system of claim 1, wherein the bioreactor supply system comprises:

a pump control system to provide one or more fluids to the bioreactor, and

a gas control system to provide one or more gasses to the bioreactor.

29. The system of claim 1, wherein the control system is configured to send signals to one or more agitation units which provide agitation to the bioreactor.

24. A system for controlling a process in a bioreactor, comprising:

a communication network;

a first sensor system connected to said communication network, said first sensor system configured to generate one or more data signals based on material or information communicated from a bioreactor to said first sensor system and provide the one or more data signals over said communication network;

a control system for automatically controlling a process in the bioreactor and connected to said communication network, said control system comprising

a controller configured with a bioreactor control process that determines and provides control signals based on the bioreactor control process and information received related to a condition in the bioreactor, the information including the one or more data signals provided by said first sensor system, and

a utility tower, housed separately from the bioreactor, said utility tower configured to receive control signals from said controller and to change a condition in the bioreactor based on the control signals, said utility tower comprising

a monitoring system that transmits information related to a condition of the bioreactor to said controller, and

a bioreactor supply system which supplies a gas or liquid substance to the bioreactor in response to a control signal received from said controller,

wherein said control system is also configured to communicate a control signal to said first sensor system, the control signal communicated to the first sensor system being based on the one or more data signals the control system received from said first sensor system, and

wherein said first sensor system is further configured to receive the control signal communicated to the first sensor system, and to perform a first action based on the received control signal.

25. The system of claim 24, wherein the first action comprises a calibration process.

26. The system of claim 24, wherein the first action comprises a diagnostic process.

27. The system of claim 24, wherein the first action comprises changing a duty cycle for communicating data signals from said first sensor system to said control system.