Overview of bioreactor control system
Maintaining optimal process conditions to achieve target yields and titers is a fundamental function of any bioprocess control system, regardless of the configuration of the bioreactor, the properties of the biocatalysts used, and process interference. Many researchers have studied the control of bioreactors in the past. The interference that causes the system to deviate from its optimal state is usually controlled by adjusting nutrient uptake, temperature, pressure, stirring, pH, DO concentration, and other key control parameters. Developing an integrated and intelligent control system does not necessarily mean developing a foolproof biological process for all possibilities, but rather focusing more on making the process more robust and efficient. Even minor improvements in efficiency and robustness can significantly enhance the economic feasibility of the product.
The optimal choice of process control and control strategies mainly depends on the type of bioreactor. The swing device, stirred tank reactor, and bubble tower reactor have been slightly modified to meet process requirements, which are currently some bioreactor platforms used in the industrial field. With the advancement of biological manufacturing processes and the introduction of new bioreactor configurations (such as disposable and micro bioreactors), the demand for more robust and process optimized complex control systems under increasingly complex operating conditions is constantly increasing.
Device/actuator level control: Classic control strategy
The actuator level control represents the most basic control level and is widely present in most machines. The actuator level control involves the actual execution of various control devices, such as pumps, valves, heaters, voltage, and agitator speed. In industrial factories, PID controllers constitute the majority of process control components at the regulatory level. PID is considered a classic controller that has achieved great success in industries such as electrical, aerospace, and mechanical applications, and is highly effective for single input single output linear systems. The PID controller has a rich history of development and industrial applications, and has developed into a commercial ready-made component that can be customized for specific applications.
With the emergence of digital progress, engineers have combined the concept of digital control with PID. The concepts of adaptive, gain scheduling, and self-tuning are easily integrated with PID control schemes, providing excellent control architectures for processes. Although PID controllers are used at the device level to control individual variables, such as temperature or pH values in bioreactors, they are not sufficient to control complex biological processes due to their highly nonlinear dynamics. In this case, feedforward process control can provide greater flexibility for optimizing process control than pure feedback control systems such as PID controllers.
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