How to enhance the automation level of integrated centrifugal concentrators?

To enhance the automation level of theintegrated centrifugal concentrator,the core lies in the full-process closed-loop control+multi-sensor fusion+intelligent algorithms+system interconnection,achieving unattended operation and adaptive optimization from sample introduction to material discharge,and from operation to maintenance. Below,a comprehensive solution is presented from five dimensions:hardware,control,software,system integration,and operation and maintenance.

1.Hardware upgrade:Building the foundation for automated perception and execution

1.Fully deploy the core sensing system(real-time closed-loop"peripheral nerve endings")

-Vacuum/pressure sensing:Equipped with a Pirani vacuum gauge and a capacitive pressure sensor,it monitors the chamber vacuum level in real time(50–100 mbar). It also integrates with a variable frequency speed regulation system for the vacuum pump,enabling PID closed-loop control of the vacuum level to prevent boiling over and sample loss.

Temperature sensing:Multi-point temperature measurement in the chamber+sample temperature probe,covering-10℃~100℃,supporting gradient programmable temperature control,temperature difference≤±0.5℃,suitable for thermosensitive samples.

-Speed/Vibration Sensing:The variable frequency motor is equipped with an encoder to achieve stepless speed adjustment and soft start/soft stop; the vibration sensor monitors the rotor dynamic balance,and automatically reduces speed/stops the machine in case of abnormalities.

-Liquid level/Density/Flow rate:Install liquid level,density,and flow rate sensors at the inlet and outlet ends to achieve automatic feeding,automatic slag discharge,automatic cavity cleaning,and to determine the concentration endpoint.

-Vision/Imaging:Equipped with an online imaging system for samples,it allows for real-time observation of the concentration status,aids in determining the endpoint,and provides early warnings for abnormalities.

-Safety sensing:door cover interlock,foam probe,leakage detection,overpressure/overtemperature/overload protection,triggering safety interlock(reducing vacuum,shutting off heating,stopping machine,alarming).

2.Intelligent transformation of executing agencies

-Drive system:Utilizing servo/variable frequency motors coupled with high-precision transmission,replacing conventional motors to achieve precise speed control and rapid response.

-Vacuum system:Equipped with a variable frequency vacuum pump,an automatic vacuum regulating valve,and a pressure relief valve,it supports delayed vacuum startup,delayed exhaust during shutdown,and automatic pressure relief upon power loss,ensuring sample protection.

-Temperature control system:electric heating+infrared assisted evaporation+refrigeration module,achieving rapid temperature rise/drop and precise temperature control.

-Material feeding/discharging and robotic arm:Integrated automatic sample feeder,robotic arm,and positioning system(positioning error<1mm)enable unmanned sample loading,rotor switching,and sampling.

-Dregs removal/cleaning:Equipped with automatic spraying and CIP(Cleaning in Place)interfaces,it achieves automatic cavity cleaning and disinfection after concentration.

3.Structure and supporting optimization

-Rotor and chamber:Adopting anti-corrosion coating and easy-to-clean design,it supports batch processing of samples of multiple specifications(50μL~50mL,96-well plates).

-Condensation recovery:Integrated solvent condensation recovery system,which is environmentally friendly and reduces energy consumption.

II. Control system upgrade:building an intelligent"brain"

1.Selection of core controller

-Utilizing PLC+motion controller+edge computing unit(such as ctrlX CORE),it supports programming languages like CODESYS and Node-RED,enabling real-time processing of multi-sensor data and coordinated execution of actuators.

-Redundant configurations are adopted for key components(power supply,CPU,network)to ensure continuous operation.

2.Full-process automation control logic

-Programmable Recipes:Equipped with over 30 sets of process recipes,preset with speed,temperature,vacuum,and time gradients based on sample types(nucleic acid,protein,organic phase),allowing for one-click access without the need for repetitive settings.

-Multi-stage automatic process:

1.Automatic self-check → Automatic balancing → Automatic door closing → Vacuum pre-pumping

2.Follow the procedure:increase speed → control temperature → control vacuum → concentrate

3.End point judgment → automatic speed reduction → delayed emptying → automatic pressure relief → door opening prompt

-Adaptive control:Based on real-time sensor data,dynamically adjust speed,vacuum,and temperature to adapt to different samples and solvents,enhancing consistency and recovery rate.

-Safety interlock:In case of overtemperature,overpressure,excessive vibration,unclosed door cover,leakage,etc.,immediate graded protection(alarm → parameter reduction → shutdown)will be triggered.

3.Human-Machine Interaction(HMI)

-An industrial touch screen with a screen size of 7 inches or larger,providing visual display of real-time parameters,trend curves,operational status,and alarm information.

-Supports local/remote operation,parameter modification,recipe management,historical data query,and report export.

-Multi-level permission management,with operation traces,meets compliance audit requirements.

III.Empowerment through Software and Algorithms:Achieving"Intelligence"Rather than Just"Automation"

1.Intelligent control algorithm

-PID+fuzzy control:Conduct multivariable coupled control of vacuum,temperature,and speed to enhance stability and response speed.

-Intelligent endpoint judgment:By integrating changes in density,vacuum,temperature,vision,and weight,it automatically identifies the concentration endpoint,avoiding over-drying or under-concentration.

-Predictive maintenance:Monitor motor current,vibration,and temperature trends,provide early warnings for bearing wear,seal aging,and pump failures,conduct maintenance in advance,and reduce unplanned downtime.

-Process optimization:Based on historical data and AI algorithms,recommend the optimal parameter combination to continuously improve efficiency and sample recovery rate.

2.Data management and analysis

-Automatic data acquisition:Record all parameters(speed,temperature,vacuum,time,alarms)in real-time,store them locally/in the cloud,and support USB and network exports.

-LIMS/SCADA Integration:Interface with laboratory information management systems or factory monitoring systems to enable data exchange,process traceability,and centralized control.

-Automatic report generation:Generate operation,quality,energy consumption,and maintenance reports by batch and time to meet compliance and management requirements.

IV.System integration and interconnection:integration into the overall automated production line/laboratory

1.Standardization of communication protocol

-Supports industrial protocols such as OPC UA,MQTT,Modbus TCP,and Profinet,enabling seamless integration with PLCs,SCADA systems,MES,robots,AGVs,and more.

-Supports WiFi/Ethernet for remote monitoring,mobile APP control,and cloud management.

2.Upstream and downstream automation linkage

-Integrate with pre-treatment/analysis equipment such as autosamplers,centrifuges,liquid chromatography,and mass spectrometry to establish an unattended sample processing pipeline.

-Interface with the factory's MES/ERP system,receive production tasks,provide feedback on operational status,and report production quantity and quality data.

3.Remote operation and maintenance and diagnosis

-Remote monitoring,parameter modification,program uploading,fault diagnosis,and software upgrading.

-Cloud-based intelligent fault database,which automatically analyzes alarms and provides solutions,and supports remote assistance.

V.Implementation Path and Benefits

1.Implement suggestions step by step

1.Basic automation:Install core sensors to achieve closed-loop control of parameters,automatic start-stop,safety interlocking,and data recording.

2.Process automation:Integrate robotic arms/automatic sample feeding to achieve unmanned operation throughout the entire process from sample feeding,concentration to discharge.

3.Intelligent optimization:Deploy AI algorithms,predictive maintenance,and cloud management to achieve adaptive control and remote operation and maintenance.

4.System integration:Interface with LIMS/MES and integrate into the overall automation system.

2.Core benefits

-Efficiency improvement:Unattended operation,24-hour operation,processing capacity increased by 50%+,labor cost reduced by 80%+.

-Quality stability:Eliminate human error,significantly improve sample consistency and recovery rate(e.g.,antibody activity retention rate>95%).

-Safety and environmental protection:Fully enclosed operation reduces solvent evaporation and cross-contamination,thereby lowering safety risks.

-Simplified operation and maintenance:Predictive maintenance reduces downtime due to failures,and remote diagnosis lowers maintenance costs.

VI.Key Considerations

-Sensor calibration:Regularly calibrate vacuum,temperature,and speed sensors to ensure measurement accuracy.

-Safety redundancy:The safety interlock adopts an independent circuit,with multiple monitoring of key parameters.

-Network security:Separate industrial networks from office networks,deploy firewalls,and regularly update patches.

-Compliance:Meet GMP,GLP,and other requirements,with traceable operations and data.

Through the comprehensive upgrade of hardware,control,software,and system integration mentioned above,the integrated centrifugal concentrator can be upgraded from a"semi-automatic device"to an intelligent automation unit,achieving efficient,stable,safe,and unmanned concentration production.