Integrated bio-reactor monitor and control system

• US 8,440,452 B2
• Filed: 09/16/2011
• Issued: 05/14/2013
• 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:
  US13/235,241
• Publication Number:
  US 20120065782A1
• Time in Patent Office: 606 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 method for controlling a process in a bioreactor, comprising:

generating one or more data signals in a sensor system comprising one or more sensors connected to the bioreactor, the one or more data signals related to a condition of the bioreactor;

transmitting the one or more data signals from the sensor system over a communication network connecting a control system, the sensor system, and a pump system, the control system comprising a controller configured with a bioreactor control process and a utility tower housed separately from the bioreactor and coupled to the controller via the communication network;

determining one or more control signals in the controller, the one or more control signals based on the bioreactor control process and on one or more data signals received in the controller from the sensor system;

communicating the one or more control signals from the controller to the utility tower;

changing a condition in the bioreactor based on the one or more control signals received in the utility tower;

communicating the one or more control signals from the control system to the pump system; and

supplying a liquid substance to the bioreactor in response to the received one or more control signals.

2. The method of claim 1, further comprising communicating a material or information related to a condition in the bioreactor from the bioreactor to the sensor system.

3. The method of claim 1, wherein the one or more data signals generated by the sensor system relate to at least one of a temperature condition of the bioreactor, a pH condition of the bioreactor, a dissolved oxygen (DO) condition of the bioreactor, a glucose condition of the bioreactor, and a concentration of dissolved oxygen condition of the bioreactor.

4. The method of claim 1, further comprising:

analyzing the one or more data signals in the controller to determine if the one or more data signals fall within a predetermined range of values;

if the one or more data signals fall within the predetermined range of values, controlling the process in the bioreactor based on the one or more data signals; and

if the one or more data signals do not fall within the predetermined range of values,

determining an action for the sensor system to perform,

generating one or more control signals corresponding to the action,

sending the one or more control signals to the sensor system, and

executing the action in the sensor system based on the one or more control signals received in the sensor system.

5. The method of claim 4, wherein the action comprises at least one of calibrating the sensor system, performing a diagnostic procedure in the sensor system, and providing an additional data signal to the controller.

6. The method of claim 1, further comprising communicating one or more control signals to a gas supply system from the control system and supplying a gas substance to the bioreactor in response to the received one or more control signals.

7. A method for monitoring conditions and controlling a process inside a chamber, comprising:

communicating a material or information from the chamber to a sensor;

generating one or more data signals based on the material or information communicated from the chamber;

transmitting the one or more data signals to a controller configured with a control process;

generating, in the controller, a first control signal and a second control signal based on the control process and the one or more data signals;

transmitting the first control signal to a utility tower housed separately from the chamber and coupled to the controller in order to perform a first action; and

transmitting the second control signal to a system coupled to the chamber and performing a second action to the chamber based on the second control signal, the second action comprising at least one of supplying a liquid substance to the chamber, supplying a gas to the chamber, changing a level of agitation of contents of the chamber, and changing a temperature inside the chamber.

8. The method of claim 7, wherein the first action comprises at least one of calibrating the sensor, performing a diagnostic procedure on the sensor, changing a condition in the chamber, and measuring a condition in the chamber.

9. The method of claim 7, wherein the one or more data signals relate to at least one of a temperature condition of the chamber, a pH condition of the chamber, a dissolved oxygen (DO) condition of the chamber, a glucose condition of the chamber, and a concentration of dissolved oxygen condition of the chamber.

10. The method of claim 7, wherein the second control action comprises removing a liquid substance or a gas from the chamber.

11. The method of claim 7, further comprising storing an electronic history related to the process occurring inside the chamber.

12. The method of claim 11, wherein the electronic history includes information on at least one of an amount of gas added or removed from the chamber, a type of gas added or removed from the chamber, an amount of liquid substance added or removed from the chamber, a type of fluid added or removed from the chamber, a duration of agitation of contents of the chamber, a speed of an impeller during agitation of contents of the chamber, a time the addition or removal of gas started, a time the addition or removal of gas ended, a time the addition or removal of liquid substance from the bioreactor started, a time the addition or removal of liquid substance from the bioreactor ended, a time agitation started, a the time agitation ended.

13. The method of claim 11, wherein the electronic history is stored in the utility tower.

14. The method of claim 11, wherein the electronic history is stored separate from the utility tower.

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

one or more processors in communication with a computer readable medium storing software code for execution by the one or more processors in order to cause the computing system to

receive sensor data signals indicative of a condition of the bioreactor from a sensor system;

determine control signals based on at least a bioreactor control process and the sensor data signals;

transmit one or more of the control signals to a utility tower, housed separately from the bioreactor, over a communication network connecting the one or more processors and the utility tower to change a condition in the bioreactor by supplying a substance to the bioreactor, agitating contents of the bioreactor, or changing a temperature of the bioreactor; and

transmit one or more of the control signals to the sensor system to change a sensing function of the sensor system.

16. The computing system of claim 15, wherein the sensor data signals relate to at least one of a temperature condition of the bioreactor, a pH condition of the bioreactor, a dissolved oxygen (DO) condition of the bioreactor, a glucose condition of the bioreactor, a concentration of dissolved oxygen condition of the bioreactor.

17. The computing system of claim 15, wherein the software code is further configured to cause the computing system to store an electronic history of the process in the bioreactor.

18. The computing system of claim 15, wherein the software code is further configured to cause the computing system to analyze the sensor data signals to determine if the sensor data signals fall within a predetermined range of values.

19. The computing system of claim 18, wherein the software code is further configured to cause the computing system to

in response to determining that the sensor data signals do not fall within the predetermined range of values, determine an action for the sensor system to perform;

generating one or more control signals corresponding to the action; and

sending the one or more control signals to the sensor system.