Integrated bio-reactor monitor and control system

• US 8,753,871 B2
• Filed: 05/13/2013
• Issued: 06/17/2014
• 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:
  US13/892,947
• Publication Number:
  US 20130245830A1
• Time in Patent Office: 400 Days
• Field of Search: 435/286.1, 435/289.1, 435/3, 700/266, 700/9, 700/17, 700/87, 366/102
• 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 of controlling a bioreactor process, comprising:

transmitting material or information about the process from a bioreactor to a first sensor system through a bioreactor connection coupling the bioreactor and the first sensor system;

communicating, through a first communication network, one or more data signals relating to the material or information from the first sensor system to a first computer coupled to the first sensor system;

communicating, through a second communication network, the one or more data signals from the first computer to a controller configured with a bioreactor control process to control the conditions in the bioreactor;

communicating information related to the one or more data signals from the controller to a utility tower housed separately and coupled to the controller;

displaying the information related to the one or more data signals on a display;

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 first sensor system;

receiving, in the first computer, the one or more control signals from the controller over the second communication network;

communicating, through the first communication network, the one or more control signals from the first computer to the first sensor system;

performing one or more control actions on the bioreactor based on the control signals received in the first sensor system.

2. The method of claim 1, wherein the first computer is located external to the utility tower.

3. The method of claim 1, wherein the first computer is located inside the utility tower.

4. The method of claim 1, further comprising communicating user input provided on the display of the utility tower to the first computer.

5. The method of claim 4, further comprising communicating, through the second communication network, the user input from the first computer to the controller.

6. The method of claim 1, wherein determining the one or more control signals comprises determining the one or more control signals based at least in part on user input provided on the display of the utility tower.

7. The method of claim 1, wherein communicating information related to the one or more data signals from the controller to the utility tower comprises communicating the information from the controller to the first computer and communicating the information from the first computer to the utility tower.

8. The method of claim 1, wherein communicating information related to the one or more data signals from the controller to the utility tower comprises communicating the information from the controller directly to the utility tower over an Ethernet connection.

9. The method of claim 1, further comprising communicating information related to one or more control signals from the first computer to the utility tower, and displaying the information related to the one or more control signals to a user on the display of the utility tower.

10. The method of claim 1, wherein transmitting material or information from the bioreactor comprises transmitting a sample of material from the bioreactor to the first sensor system through a tube coupling the bioreactor and the first sensor system.

11. The method of claim 10, further comprising analyzing, in the first sensor system, the sample to determine a condition or a characteristic of a solution in the bioreactor.

12. The method of claim 11, wherein the condition of the solution is one of a temperature condition, a pH condition, a dissolved oxygen (DO) condition, a glucose concentration condition, a concentration of dissolved oxygen condition, a concentration of dissolved carbon dioxide condition, a concentration of lactose condition, and an optical density condition, and wherein the characteristic of the solution is one of a molecular characteristic, a cell density characteristic, a cell viability characteristic, a presence of an amino acid in the solution, and a weight of the solution.

13. The method of claim 1, wherein transmitting information about the process comprises transmitting signals from the bioreactor to the first sensor through an electrical, mechanical, or optical communication structure coupling the bioreactor and the first sensor system.

14. The method of claim 13, wherein the information about the process includes one of a temperature condition, a pH condition, a dissolved oxygen (DO) condition, a glucose concentration condition, a concentration of dissolved oxygen condition, a concentration of dissolved carbon dioxide condition, a concentration of lactose condition, an optical density condition, a molecular analysis, a cell density, information on cell viability, information on the presence of an amino acid, and a weight of a solution in the bioreactor.

15. The method of claim 1, wherein performing one or more control actions comprises supplying a substance to the bioreactor, removing a substance from the bioreactor, and agitating a solution in the bioreactor.

16. The method of claim 1, further comprising:

transmitting material or information about the process from the bioreactor to a second sensor system through a bioreactor connection coupling the bioreactor and the second sensor system;

communicating, through a third communication network, one or more data signals relating to the material or information from the second sensor system to a second computer coupled to the second sensor system; and

communicating, through a fourth communication network, the one or more data signals from the second computer to the first computer.

17. The method of claim 16, further comprising:

communicating, via the first computer and the second computer, one or more control signals from the controller to the second sensor system; and

performing one or more control actions on the bioreactor based on the control signals received in the second sensor system.

18. The method of claim 1, wherein the controller continuously receives a plurality of data signals from the first sensor system relating to a cell growth condition in the bioreactor, the controller continuously analyzes the data signals to determine if the cell growth condition falls within a predetermined range of values, and, if the cell growth condition falls within the predetermined range of values, the controller initiates a control action to harvest a portion of cells from the bioreactor.

19. The method of claim 1, wherein the bioreactor process comprises cell culture growth, microbial fermentation, semiconductor fabrication, or liquid chromatography.

20. A method of controlling a bioreactor process, comprising:

transmitting material from a bioreactor, being used to perform a bioreactor process, to a first sensor system through a bioreactor connection, the bioreactor connection coupling the bioreactor to the first sensor system;

communicating, through a first communication network, one or more data signals relating to the material from the first sensor system to a computer coupled to the first sensor system;

communicating the one or more data signals from the first computer to a controller configured with a bioreactor control process to control the conditions in the bioreactor;

communicating information related to the one or more data signals from the controller to a utility tower housed coupled to the controller, the utility tower housed separately from the bioreactor;

displaying the information related to the one or more data signals on a display connected to the utility tower;

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

performing, based on the one or more control signals, one or more control actions on the bioreactor, the one or more control actions comprising supplying a liquid or a gas to the bioreactor from the utility tower and agitating material in bioreactor.