METHOD FOR CREATING A MAINTENANCE PROGRAM

Abstract

A method for generating a maintenance program for the operation of a maintenance system at a bioreactor, in particular a bioreactor of a vehicle for transporting persons, which method comprises at least the following steps, which are executed by an electronic data processing means associated with the maintenance system: acquiring system characteristics data of the maintenance system; acquiring reactor characteristics data of the bioreactor, the reactor characteristics data being received at least in part from a communication interface of the bioreactor; and generating the maintenance program at least on the basis of the system characteristics data and the reactor characteristics data.

Claims

1-21. (canceled)

22. A method for generating a maintenance program for the operation of a maintenance system on a bioreactor of a vehicle for transporting persons, the method comprising at least the following steps, which are carried out by an electronic data processing means associated with the maintenance system: acquiring system characteristics data of the maintenance system; acquiring reactor characteristics data of the bioreactor, wherein said reactor characteristics data are received at least in part from a communication interface of the bioreactor; and generating said maintenance program at least on the basis of said system characteristics data and said reactor characteristics data.

23. The method according to claim 22, wherein the maintenance system includes at least one system container which is in communication with a plurality of system lines of the maintenance system; and wherein the system characteristics data represents at least one predefined system characteristic value of the system container and/or the system lines.

24. The method according to claim 22, wherein the bioreactor includes at least one reactor vessel which is connected to a plurality of reactor lines of the bioreactor, wherein the reactor characteristics data represent at least one predefined reactor characteristic value of the reactor vessel and/or the reactor lines, in particular wherein the reactor characteristics data comprise reactor identification data which are uniquely assigned to the reactor characteristic value.

25. The method according to claim 22, wherein the system characteristics data represent at least one system operating state value and/or wherein the reactor characteristics data represent at least one reactor operating state value, in particular wherein the system operating state value and/or the reactor operating state value indicate a deviation from a predefined operating state.

26. The method according to claim 22, wherein generating the maintenance program comprises adapting a predefined maintenance program at least based on the system characteristics data and the reactor characteristics data.

27. The method according to claim 22, wherein the system characteristics data and/or the reactor characteristics data are updated, and wherein the maintenance program is adapted or newly generated on the basis of the updated system characteristics data and/or reactor characteristics data.

28. The method according to claim 22, wherein the system characteristics data and/or the reactor characteristics data are automatically updated based on an event and/or based on time intervals.

29. The method according to claim 22, wherein the maintenance program comprises a plurality of operating parameters that determine a maintenance program sequence, wherein generating the maintenance program comprises applying at least one calculation rule, and wherein the at least one calculation rule represents a predefined relation between at least the plurality of operating parameters, the system characteristics data, and the reactor characteristics data.

30. The method according to claim 22, including: acquiring maintenance characteristics data for the maintenance program, wherein the maintenance program is generated on the basis of the maintenance characteristics data.

31. The method according to claim 30, wherein the maintenance characteristics data includes a maintenance history of the bioreactor, preferably wherein the maintenance history is part of the reactor characteristics data.

32. The method according to claim 30, wherein the maintenance system includes a user interface, wherein acquiring system characteristics data and/or reactor characteristics data and/or maintenance characteristics data for the maintenance program comprises acquiring input data which are entered by a user of the maintenance system at the user interface.

33. The method according to claim 22, wherein a cleaning program for cleaning the bioreactor is part of the maintenance program and/or wherein a test program for testing components of the bioreactor is part of the maintenance program.

34. The method according to claim 22, wherein the electronic data processing means is formed by an electronic data processing unit of the maintenance system, wherein the electronic data processing unit is connected to at least a first interface and a second interface of the maintenance system, wherein the system characteristics data is received at least partially at the first interface, and wherein the reactor characteristics data is received at least partially at the second interface from the communication interface of the bioreactor.

35. A device for generating a maintenance program for the operation of a maintenance system on a bioreactor, in particular a bioreactor of a vehicle for transporting persons, the device comprising an electronic data processing means associated with the maintenance system for carrying out the method according claim 22.

36. A computer program comprising instructions that, when the computer program is executed by an electronic data processing means, cause the electronic data processing means to execute the method of claim 22.

37. A method of operating a maintenance system on a bioreactor, in particular a bioreactor of a vehicle for transporting persons, the method comprising operating the maintenance system by a maintenance program generated by a method according to claim 22.

38. The method of claim 37, including transmitting control data from the maintenance system to the bioreactor to operate the bioreactor in response to the control data.

39. The method according to claim 38, including transmitting reactor characteristics data, in particular reactor operating state values, from the bioreactor to the maintenance system.

40. A computer program comprising instructions that, when the computer program is executed by an electronic data processing means, cause the electronic data processing means to execute the method of claim 37.

41. A maintenance system for maintaining a bioreactor, in particular a bioreactor of a vehicle for transporting persons, wherein the maintenance system comprises an interface for transmitting data between the maintenance system and the bioreactor.

42. The maintenance system for maintaining a bioreactor, in particular a bioreactor of a vehicle for transporting persons, wherein the maintenance system comprises an interface for transmitting data between the maintenance system and the bioreactor; and wherein the maintenance system is adapted to perform the method according to claim 22.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Further advantages, features, and aspects of the invention will be apparent from the following description and from the drawings. The drawings show in:

[0055] FIG. 1 is a schematic representation of the maintenance system in connection with a bioreactor and other elements;

[0056] FIG. 2 is a schematic side view of the maintenance system, partially cut away;

[0057] FIG. 3 is a circuit diagram of the maintenance system;

[0058] FIG. 4 is a first example of a cleaning process;

[0059] FIG. 5 is a second example of a cleaning process;

[0060] FIG. 6 is a schematic view of a maintenance system, a bioreactor and an electronic data processing means for generating a maintenance program; and

[0061] FIG. 7 is a schematic view of process steps for a method of generating a maintenance program.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0062] A maintenance system 1 can be designed as a mobile maintenance system, as shown in FIG. 1, or as a stationary maintenance system. A mobile maintenance system can typically be moved to a train in which a bioreactor 2 is arranged. Bioreactors 2 in trains are generally known and will not be described in detail here. In FIG. 1, a vertically oriented bioreactor 2 is shown as an example, with a solids tank 4, a liquid tank 5, and a sanitizing unit 6, which has an outlet 7 for draining liquids. A filter basket 8 is provided in the solids tank 4, into which both a 2-inch hose 9 terminates near the bottom, and a cleaning nozzle 10 is provided to supply water under high pressure to the solids tank 4 to clean off a filter cake built up in the filter basket 8. A 1-inch connection 11 is provided on the liquid tank 5 to draw or suction liquid from or supply liquid to the liquid tank 5. Further, the bioreactor 2 comprises a controller 12 that can, for example, read sensors of the bioreactor 2.

[0063] The maintenance system 1 has connections via which it can be connected to the bioreactor 2. For example, in order to draw off liquid from the bioreactor 2, the maintenance system 1 has a first suction connection 20, which can be connected to the 1-inch connection 11 of the liquid tank 5 of the bioreactor 2 via a first suction line 22. Furthermore, the maintenance system 1 has a second suction connection 24, which can be connected to the 2-inch hose 9 of the bioreactor 2 via a second suction line 26, in order to suction or draw off liquid from the bioreactor 2, more specifically the solids tank 4, via the latter, in order to remove filter cake formed there. However, liquid can also be added to the bioreactor 2 via the 2-inch hose 9 for cleaning purposes, as will be described in more detail below The maintenance system 1 also has a high-pressure connection 28, which can be connected to the cleaning nozzle 10 via a high-pressure hose 30, and an electronic control connection 32, which can be connected to the control 12 of the bioreactor 2 via a signal line 34.

[0064] The maintenance system 1 further has a disposal connection 36, via which the maintenance system 1 can be connected to an external tank 38 or a sewer system, which is connected to an external vacuum source 39, for extracting liquid from the maintenance system 1. On the input side, the maintenance system 1 has a voltage connection 40 and a fresh water connection 42.

[0065] Inside the maintenance system 1 (FIG. 2), an electronic control unit 44 which has a memory with program code and a processor for executing the program code, is provided. The electronic control unit 44 controls various functions of the maintenance system 1, as is apparent in particular from the further description. For example, the electronic control unit 44 controls a pump 46 as well as a high pressure pump 48. The pump 46 may be used to provide a vacuum at the first suction connection 20 or the second suction connection 24, as well as to pump fluid to the second suction connection 24. The high pressure pump 48 is used to provide a fluid at high pressure to the high pressure port 28. Furthermore, a collection tank 50 and an acid tank 52 are provided inside the maintenance system 1, wherein a first level sensor 51 is provided for the collection tank 50 and a second level sensor 53 is provided for the acid tank 52. On the left-hand side of the maintenance system 1 in FIG. 2, a human-machine interface 54 is arranged, which comprises, for example, a touch display. Via this human-machine interface 54, for example, the electronic control unit 44 can be operated and, for example, parameters or the like can be entered. A maintenance program can also be generated via the human-machine interface 54. For this purpose, input data can be entered at the human-machine interface 54 and used to generate the maintenance program. The generation of a maintenance program will be explained in further detail with reference to FIGS. 6 and 7.

[0066] A warning light 56 is optionally provided on a top surface of the maintenance system 1, which is adapted to emit light in different colors for indicating a status, a fault, or the like of the maintenance system 1.

[0067] FIG. 3 now shows a complete layout or circuit diagram of the mobile maintenance unit 1, in which the pump 46 as well as the first suction port 20, the second suction port 24, the flushing port 28, the disposal port 36 and the fresh water port 42 are shown. Furthermore, the high-pressure pump 48 is shown. Not shown in FIG. 3 are the electronic connections as well as the electronic control unit 44, but it is to be understood that the electronic control unit 44 is actually connected to the pump 46 as well as the high pressure pump 48, and also to some or all of the other valves and sensors described below. The layout of a stationary maintenance system may differ slightly in details, but the functionality is essentially the same and stationary maintenance systems are also encompassed by the invention.

[0068] In FIG. 3, the maintenance system 1 is shown subdivided into four systems, namely a system A, which includes the pump 46 as well as the high pressure pump 48, and which also includes the first and second suction ports 20, 24, as well as the flushing port 28. A system B is shown within system A and including a measuring unit 60, which will be described in more detail. System C includes an acid dosing unit 62, and system D includes the collection tank 50, the acid tank 52, the corresponding associated level sensors 51, 53, and the disposal connection 36.

[0069] The pump 46 has a first pump port 64 and a second pump port 66, and the pump 46 is preferably configured as a rotary pump and can pump fluid from the first pump port 64 to the second pump port 66 as well as vice versa from the second pump port 66 to the first pump port 64.

[0070] A first line L1 extends from the first suction connection 20 in the direction of the first pump port 64. The first line L1 is connected to a first valve BV9, which in turn is connected to a second line L2. The first valve BV9 is designed as an electrically switchable ball valve and can be controlled by the electronic control unit 44. Other types of valves, such as switching valves, are also preferred. Now, it is important in the context of the invention that some of the valves are electrically switchable by the electronic control unit 44. A ball valve has the advantage that the flow through the valve is continuously adjustable. Moreover, in the embodiment shown, a first manual valve HH1 is placed in the first line L1, which allows manual opening and closing of the first line L1. A first capacitive sensor VF1 is also provided between the first valve BV9 and the first manual valve HH1, which senses the presence of fluid in the first line L1 and provides a signal representing the presence of fluid in the first line L1 to the electronic control unit 44.

[0071] Here, the second valve BV10 is connected to the first pump connection 64, more specifically to a first pump line PL1 that originates from the first pump connection 64. With reference to FIG. 3, the first pump line PL1 leads left wise to system D.

[0072] The second suction connection 24 is connected to a third line L3, which is connected to a fourth line L4 via a third valve BV8. Again, a second manual valve HH2 is placed in the third line L3, which allows manual opening and closing of the third line L3. A second capacitive sensor VF2 is placed between the second manual valve HH2 and the third valve BV8, which also detects the presence of fluid there and provides a corresponding signal representing the presence of fluid to the electronic control unit 44. A first pressure sensor PT1 is also provided in the first line L1 and a second pressure sensor PT2 is provided in the third line L3, which detect pressure in the first and third lines L1, L3 and provide corresponding first and second pressure signals to the electronic control unit 44. The fourth line L4 is connected to the second pumping port 66 via a fourth valve BV5, more specifically to a second pumping line PL2. The second pump line PL2 connects the second pump port 66 to the fourth valve BV5.

[0073] According to the embodiment shown here, a bypass is also provided between the second line L2 and the fourth line L4, namely in the form of a bypass line BL which can be closed by a fifth valve BV7. The bypass line BL is used to allow not only the first suction port 24 to be connectable to the first pump port 64 via the first line L1 and the second line L2, but the first suction port 20 is also connectable to the second pump port 66 via the first line L1, the bypass line BL and the fourth line L4. In a corresponding manner, the second suction port 24 is also connectable to the second pump port 66 not only via the third and fourth lines L3, L4, but also via the third line L3, the bypass line BL, and the second line L2 and the first pump line PL1. Depending on the directions in which liquids should be pumped, this is advantageous.

[0074] If, for example, liquid is extracted from the bioreactor 2 in a first cleaning step, this is done via the second suction connection 24. For this purpose, the second manual valve HH2 is to be opened, at the same time the electronic control unit opens the third valve BV8 and the fourth valve BV4 and the pump conveys the extracted liquid from the second pump port 66 to the first pump port 64 in the first pump line PL1. The second valve BV10 is closed and liquid flows through the first pump line PL1 towards system D. In system D, the collection tank 50 is connected to the first pump line PL1 via a first collection tank valve BV82 and the acid tank 52 is connected to the first pump line PL1 via a first acid tank valve 85. Thus, in order to convey the extracted liquid from the second suction connection 24 into the collection tank 50, the electronic control unit 44 also opens the first collection tank valve 82. If liquid is now additionally to be extracted from the liquid tank 5 of the bioreactor 2 via the first suction connection 20, the first manual valve HH1 must be opened. The electronic control unit 44 then opens the first valve BV9, the fifth valve BV7 and the fourth valve BVS. In this way, the first suction connection 20 is connected to the second pump port 66. The pump 46 can then, in turn, pump from the second pumping port 66 to the first pumping port 64, thereby delivering the fluid extracted via the first suction port 20 to the collection tank 50 via the first collection tank valve 82.

[0075] The collection tank 5 is emptied into the disposal tank 38 or into the sewer system via a third manual valve HH50, which connects the collection tank 50 to the disposal connection 36.

[0076] In system D, in particular, differences exist between the mobile maintenance system 1 shown here and a stationary maintenance system. For example, a separate additional pump may be provided to empty the collection tank 50 and the acid tank 52, preferably in the form of a double pump. In addition, a further pump is preferably provided, again in the form of a double pump, for filling the acid tank 52 with acid and for filling the acid from the acid tank into the respective connected bioreactor. By means of the further pump, in this case, circulation of the liquid through the bioreactor can also be carried out. In addition, a stationary system can have an additional connection for providing freshwater for a catering service in the railcar, as well as another additional connection for providing freshwater for hand washing and/or toilet flushing. A branch line for this additional connection preferably branches off directly from the freshwater connection 42, so that no contamination can take place here.

[0077] Also connected to the fourth line L4 is a sixth valve BV6, which connects the fourth line L4 to a first measuring line ML1. The first measuring line ML1 leads on the one hand to the measuring unit 60, and on the other hand to an eighth valve BV1, which is connected to a first freshwater line FL1 via a first flow sensor FT1. The first fresh water line FL1 is connected to the freshwater connection 42 via a check valve 68 and thus receives freshwater from the freshwater connection 42. If, for example, freshwater is to be fed into the filter basket 8 of the bioreactor 2 via the second suction connection 24, the eighth valve BV1, the sixth valve BV6 and the third valve BV8 must then be opened for this purpose. Freshwater is already provided under a certain pressure via the freshwater connection 42, and can thus be fed directly into the bioreactor 2 with sufficient pressure. However, if freshwater under increased pressure is to be supplied to the cleaning nozzle 10 via the flushing connection 28, a ninth valve MV1, which is designed here as a solenoid valve, must first be opened for this purpose. The ninth valve MV1 connects the first freshwater line FL1 downstream of the first flow sensor FT1 to the high-pressure pump 48, which can then provide freshwater under high pressure to the flushing connection 28. The ninth valve MV1 and the high pressure pump 48 are also controlled by the electronic control unit 44.

[0078] The freshwater port 42 is further connected to the acid dosing unit 62 via a second freshwater line FL2. The acid dosing unit 62 includes a plurality of acid canister ports 70, and a plurality of base canister ports 80. The acid canister ports 70 are connected to acid canisters 72, and the base canister ports 80 are connected to base canisters 82. The acid and base canisters 72, 82 can be interchanged and are stored, for example, at the lower portion of the maintenance system 1. The second freshwater line FL2 leads to a tenth valve BV78, and from there to a second flow sensor FT60. Downstream of the second flow sensor FT60, a third pressure sensor PT60 and a first pH sensor QT60 are provided. The second flow sensor FT60, the third pressure sensor PT60, and the first pH sensor QT60 can be used to detect values of the fluid present in the first dosing line DL1. Downstream of the first pH sensor QT60, the first dosing line DL1 branches into an acid line S1, a second dosing line DL2, and a first base line B1. The first acid line S1 leads to an acid doser 74, which is designed here as an acid ejector and, in addition to liquid from the first dosing line DL1 or first acid line S1, also receives undiluted acid via a second acid line S2, which is connected to the acid canister connections 70. An eleventh valve MV71, which is designed as a solenoid valve, is inserted into the second acid line S2. It serves to seal off the acid canister connections 70 from the second acid line S2. Downstream of the acid doser 74, a twelfth valve BV60 is provided, which is again designed as a ball valve and is again controlled by the electronic control unit 44. The twelfth valve BV60 connects the acid doser 74 to a third acid line S3, which leads to a mixer 90. The mixer 90 may comprise, for example, a static mixer having a mixing element.

[0079] On the other side, the first base line B1 connects the second flow line DL2 to a base dosing unit 84, which is designed here as a base ejector. The base dosing unit 84 receives not only liquid via the first base line B1, but also undiluted base via a second base line B2. A thirteenth valve MV73 is placed in the second base line B2, which is formed as a solenoid valve, and is controlled by the electronic control unit 44. The thirteenth valve MV73 serves to seal off the base canister connections 80 from the second base line B2 or the base doser 84. Downstream of the base doser 84, a fourteenth valve BV62 is provided, which is again a ball valve and is controlled by the electronic control unit 44. The fourteenth valve BV62 connects the base doser 84 to a third base line B3, which also opens into the mixer 90. Thus, a fluid having a specific pH can be generated in the mixer 90 via this arrangement. Downstream of the mixer 90, the mixer 90 opens into a third dosing line DL3 in which a second pH sensor QT61 is inserted to provide a second pH signal to the electronic control unit 44. The third dosing line DL3 branches into a fourth dosing line DL4, which leads to the acid tank 52 or collection tank 55, and a fifth dosing line DL5, which leads back to system A. The fourth dosing line DL4 is connected to a second acid tank valve BV83 and a second collection tank valve BV80, so that liquid from the fourth dosing line DL4 can be selectively fed to the acid tank 52 or collection tank 50 via the second acid tank valve BV83 and the second collection tank valve BV80. This is particularly important if an aqueous acid solution is to be generated in the acid tank 52. To this end, the electronic control unit 44 controls the tenth valve BV78, the eleventh valve MV71, the twelfth valve BV60, the fourteenth valve BV62, and the thirteenth valve MV73 such that a liquid having a predetermined desired pH can be provided in the fourth dosing line DL2 and thus enter the acid tank 52.

[0080] Aqueous acid solution is used, in particular, to chemically clean the bioreactor 2 for removing lime deposits on it. For this purpose, aqueous acid solution must be fed from the acid tank 52 to the first and/or second suction ports 20, 24. This is effected by the pump 46, which is connected to the acid tank 52 in an appropriate manner. For example, if aqueous acid solution is to be provided to the first suction port 20, the electronic control unit 44 opens the first acid tank valve BV85, the fourth valve BV5, the fifth valve BV7, and the first valve BV9. Aqueous acid solution is then provided via the first pump line PL1, from the first pump port 64 to the second pump port 66 and via said valves to the first suction port 20. In a corresponding manner, aqueous acid solution can also be provided at the second suction port 24, in which case, in deviation from the aforementioned, the fifth and first valves BV7, BV9 do not have to be opened, but instead only the third valve BV3.

[0081] If an aqueous acid solution has been used to clean the bioreactor 2, it is also necessary to extract it again from the bioreactor 2. This is done via the first suction connection 20. If an aqueous acid solution is suctioned out of the bioreactor 2 via the suction connection 20, the first valve BV9, the fifth valve BV7, the fourth valve BV5 and the first acid tank valve BV85 are opened for this purpose. The pump 46 then pumps the aqueous acid solution from the second pump port 66 to the first pump port 64, and consequently into the acid tank 52.

[0082] If the aqueous acid solution in the acid tank 52 is to be neutralized, the electronic control unit 44 controls the acid dosing unit 62 accordingly to provide a liquid suitable for neutralizing the aqueous acid solution in the acid tank 52. It is also possible to achieve flow-through neutralization. For this purpose, aqueous acid solution is drawn from the acid tank 52 via the first acid tank valve 85 by means of the pump 46, pumped from the first pumping port 64 to the second pumping port 66, and from there via a return valve BV3 connecting the second pumping line PL2 or the second pumping port 66 to the acid metering unit 62. More specifically, a return line RL leads from the return valve BV3 to the second fresh water line FL2 and opens into it downstream of the tenth valve BV78 but upstream of the first flow meter 60. By means of the first pH sensor QT60, the pH of the aqueous acid solution thus recycled from the acid tank 52 can then be determined and the valves BV60, BV62 and a restriction BV61 can be controlled so that sufficient base is added to the aqueous acid solution provided through the recycle line RL3 to neutralize it. After the solution has been neutralized in the acid tank 52, it can be conveyed to the collection tank 50 by means of the pump 46.

[0083] To improve cleaning of the bioreactor 2 with aqueous acid solution, air can also be introduced into the aqueous acid solution via the first suction connection 20 in the form of bubbles. For this purpose, a compressor 92 is provided, which is connected to the first line L1 via a compressor line 93 and a compressor valve MV2, and can thus feed compressed air into the first line L1. The compressor 92 and the first compressor valve MV2 can also be controlled by the electronic control unit 44.

[0084] The measuring unit 60 is constructed and connected to the further elements as follows: The measuring unit 60 comprises a measuring chamber 96 with a first port 97, a second port 98 and a third port 44. The first port 97 is connected to the second pump line PL2 via a first measuring valve BV41, in particular, via a second measuring line ML2. The second port 98 is connected to the first measuring line ML1 via a second measuring valve BV40, and the third port 44 is also connected to the first measuring line ML1 via a third measuring valve BV43. A level sensor LT40 is further provided at the measuring chamber 96, which is connected to the electronic control unit 44 and can provide a measuring level signal thereto. The measuring unit 60 is used to test the permeability of the bioreactor 2 after cleaning has been performed. For this purpose, a predetermined volume of freshwater is first metered in the measuring chamber 96. This is preferably done by opening the eighth valve BV1 and the second measuring valve BV40. In this way, freshwater can flow through the second port 98 into the measuring chamber 96 until a predetermined volume is reached, which is determined by means of the measuring level signal.

[0085] After the predetermined volume has been metered in the measuring chamber 96, it can be supplied to the bioreactor 2 via the second suction port 24. For this purpose, the first measuring valve BV41 is opened, the liquid is pumped from the second pumping port 66 to the first pumping port 64, then further via the second valve BV10, the bypass line BL, the fifth valve BV7 as well as the third valve BV8 to the second suction port 24. Subsequently, a predetermined time is waited until the liquid has passed through the bioreactor 2. Subsequently, the liquid is extracted from the liquid tank 5 via the first suction connection 20 by opening the first valve BV9 and the second valve BV10, the liquid is pumped from the first pumping port 64 to the second pumping port 66 and then introduced into the measuring chamber 96 via the fourth valve BV5, the sixth valve BV6, and the third measuring valve BV43. There, the extracted fluid is measured again. If the volume difference between the supplied liquid and the extracted liquid does not exceed a predetermined threshold, the cleaning is okay. If the volume difference exceeds a predetermined threshold, the cleaning is not okay and a corresponding warning signal can be output, for example, via the warning light 56 and/or the human-machine interface 54. The comparison of whether or not the volume difference exceeds the predetermined threshold is preferably performed by the electronic control unit 44.

[0086] Referring now to FIG. 4, an example of a cleaning procedure which may be defined by a maintenance program for operating the maintenance system 1 on the bioreactor 2 is illustrated. The cleaning method as such is disclosed herein. However, it is to be understood that the maintenance program, which may be stored on and/or executed by the control unit 44 of the maintenance system 1, causes the maintenance system 1 to perform the cleaning method. The cleaning method explained in FIG. 4 may comprise, for example, the number of steps described below, although the method may also comprise more or fewer steps. The cleaning method basically works cyclically and can be performed as a mechanical cleaning procedure, in which no acid is introduced into the bioreactor 2, or as a chemical cleaning procedure, in which acid is used to clean the bioreactor 2.

[0087] In step S10, freshwater is first introduced into the bioreactor 2 from the freshwater connection 42 via the second suction connection 24. For this purpose, the electronic control unit 44 switches the corresponding valves and controls the pump 46, as basically described above. In this first step S10, preferably about 50 liters of water are introduced into the bioreactor 2. This should take about 1 minute. In step S11, liquid is then extracted from the bioreactor 2 via the second suction connection 24 and pumped into the collection tank 50. For this purpose, the electronic control unit 44 also controls the corresponding valves and the pump 46. This is preferably carried out until the second capacitive sensor VF2 detects that there is no more liquid in the line L3. Step S12 is then optional and in this step liquid is extracted from the bioreactor via the first suction connection 20. This is not mandatory, but can be implemented to clean the bioreactor of this liquid. Subsequently, in step S13, liquid, preferably freshwater, is again preferably added to the bioreactor 2 via the second suction port 24. Liquid can also be added to the bioreactor 2 via the first suction port 20 in step S15. This both serves to flush up solids in the bioreactor 2. In step S16, additional mechanical cleaning is then preferably carried out by providing freshwater under high pressure via the flushing connection 28. For this purpose, the electronic control unit 44 controls the corresponding valves, namely, in particular, the ninth valve MV1 as well as the high-pressure pump 48. During this flushing with high pressure, preferably only 40% of the bioreactor volume is filled with water. Depending on the bioreactor 2, this can correspond to a volume of approximately 70 to 100 liters.

[0088] In step S17, liquid is then again extracted from the bioreactor 2 via the second suction connection 24, and in step S18, liquid is also extracted via the first suction connection 20. In both, step S17 and step S18, extraction or suctioning preferably continues until the first and second capacitive sensors VF1, VF2 detect that there is no liquid left in the first and third lines L1, L3, respectively. Steps S19 to S23 are then preferably repetitions of steps S14 to S18 and may be repeated as many times as necessary to achieve sufficient cleaning. However, it may be envisaged that higher filling levels of the bioreactor 2 are also allowed in the subsequent steps in which liquid is supplied via the flushing connection 28, for example 60, 70 or 80%. It can also be provided that in step S18 as well as in step S23, initially no suction is provided via the first suction connection 20, but that this liquid remains in the bioreactor 2. Only in the last step, before the process is terminated, suction is applied via the first suction connection 20 in order to completely empty the bioreactor 2, in particular, the liquid tank 5.

[0089] FIG. 5, on the other hand, illustrates a chemical cleaning process and thus another example of the cleaning method, which may be defined by a maintenance program for operating the maintenance system 1 on the bioreactor 2. However, it should be understood that the mechanical cleaning process according to FIG. 4 may also be combined with the cleaning method according to FIG. 5. For example, the mechanical cleaning procedure according to FIG. 4 is carried out first as part of the cleaning method, followed by the chemical cleaning procedure according to FIG. 5.

[0090] In step S30, an aqueous acid solution, which has already been provided in the acid tank 52, is supplied to the bioreactor 2 via the first suction connection 20. Subsequently, aqueous acid solution is also supplied to the bioreactor 2 via the second suction connection 24. This can also be done simultaneously with step S30. Alternatively, it is also possible to perform step S31 before step S30. Subsequently, after the aqueous acid solution has been supplied to the bioreactor 2, a waiting time takes place in step S32. This waiting time preferably is at least 5 minutes, preferably it is in the range of 5 minutes to 1 hour, preferably 20 minutes to 30 minutes. This is a sufficient time to clean lime deposits to a large extent. Subsequently or simultaneously, compressed air can also be introduced into the bioreactor 2 by means of the compressor 92 in step S33. The compressor 92 is also controlled by the electronic control unit 44 so that it provides an appropriate signal in step S33. In step S34, a circulation of aqueous acid solution through the bioreactor 2 can be carried out. For this purpose, aqueous acid solution is preferably introduced into the bioreactor 2 via the second suction connection 24 and extracted via the first suction connection 20. For this purpose, the electronic control unit 44 preferably opens the first valve BV9, the second valve BV10, the fourth valve BVS, and the third valve BV3. The pump 46 is driven to pump the fluid from the first pump port 64 to the second pump port 66. In this manner, circulation of the aqueous acid solution through the bioreactor 2 can be effected. During this circulation, air can additionally be introduced into the liquid in the form of bubbles, preferably by means of the compressor 92. The air bubbles in the liquid cause mechanical cleaning of the lines as well.

[0091] However, it is also possible to pass the aqueous acid solution that has been extracted from the bioreactor 2 via the first extraction port 20 through the acid dosing unit 62, for example, to dose additional acid.

[0092] In step S35, a pause is made and a certain time is waited. This time is again used to allow the aqueous acid solution to act in order to dissolve the lime deposits. It can be of a similar time range as mentioned above, preferably again in the range of 20 to 30 minutes. Then, in step S36, compressed air is preferably again introduced through the first suction connection 22, and in step S37, the aqueous acid solution is circulated in the bioreactor 2. Steps S35 to S37 may then follow this several times, so that several cycles of pause (step S35), introduction of compressed air (S36) and circulation of the aqueous acid solution in the bioreactor 2 (S37) are carried out. For example, five cycles of this can be performed.

[0093] Then, in step S38, the aqueous acid solution is extracted from the bioreactor 2 via the first suction connection 20 and supplied to the acid tank 52. This is effected by means of the pump 46 by opening the first valve BV9, the fifth valve BV7, the fourth valve BV5, and the first acid tank valve BV85. The pump 46 then pumps the aqueous acid solution from the second pump port 66 to the first pump port 64 and into the acid tank 52. For flushing the bioreactor of residual acid, freshwater is preferably introduced both at step S39 through the second suction connection 24 and at step S40 through the first suction connection 20. Optionally, freshwater is also introduced through the flushing port 28. This water thus supplied for flushing is preferably subsequently extracted in step S41 and step S42 via the first and second suction connection 20, 24 and pumped into the collection tank 50.

[0094] As an alternative to this neutralization in the acid tank 52, neutralization can also be carried out in the bioreactor 2 itself. This can save freshwater for rinsing.

[0095] For this purpose, the aqueous acid solution to be neutralized is preferably first suctioned out of the bioreactor 2 into the acid tank 52, preferably via the first suction connection 22. Freshwater is then preferably introduced into the bioreactor 2 in order to flush it a first time. This can be done either via the flushing connection 28 or via the second suction connection 24. The liquid then present in the bioreactor is acidic and must be further neutralized. The liquid can now be extracted via the first suction connection 20, and passed over the acid dosing unit, where it is mixed with base, and fed back into the bioreactor 2. This cycle or cycling can be repeated until a sufficiently neutral pH is achieved. Subsequently, the neutralized liquid can be suctioned out of the bioreactor 2, preferably via the first suction connection 22, and then either fed into the collection tank 50 or directly into a sewer drain. In this way, the bioreactor 2 is flooded with freshwater only once for rinsing, whereas it would have to be rinsed several times if the liquid used for rinsing had to be neutralized in the acid tank 52 after each rinse. This procedure is particularly efficient for mobile maintenance systems that have base canisters containing high doses of base. In stationary systems, on the other hand, diluted base is generally used in order to simplify the tubing or piping between the maintenance system and the bioreactor.

[0096] Simultaneously or subsequently, the aqueous acid solution in the acid tank 52 can be neutralized or first tested for its pH content. If the aqueous acid solution is extracted from the bioreactor 2 via the first suction connection 20, it is also conceivable not to pump it directly into the acid tank 52, but by opening the valves BV9, BV10, BV3 to feed it to the acid dosing unit 60 and from there via the second acid tank valve BV83 into the acid tank 52.

[0097] The individual steps described herein may also be performed in other sequences, in other combinations, or multiple times. This may be performed based on sensor data or parameters sensed by the electronic control unit 44. For example, the number of repetitions of a circulation of the aqueous acid solution (steps S35 to S37) may be carried out depending on the type of bioreactor read-out from the bioreactor by the electronic control unit 44. Further parameters which may have an influence on this are also the time lapsed since the last cleaning interval, the operating age of the bioreactor, and the like. Such data can be recorded, in particular, as part of the method described below for generating a maintenance program.

[0098] With reference to FIG. 6, aspects of the maintenance system 1 and the bioreactor are described that enable automatic generation of a maintenance program, in particular, for carrying out the described cleaning procedures. The bioreactor 2 includes an interface 95 for transmitting reactor characteristics data of the bioreactor 2 to the maintenance system 1 via a wired connection, the reactor characteristics data being received at an interface 96 of the maintenance system 1. Control data can also be transmitted to the bioreactor 2 via the interfaces 95 and 96 in order to operate parts of the bioreactor 2, for example, the sanitizing unit 6 during the execution of the maintenance program. The maintenance system 1 further comprises the control unit 44, which comprises a memory (not shown) in which system characteristics data and a program code for generating a maintenance program are stored. The maintenance system 1 further comprises a wireless interface 98 for transmitting data. Active wireless connections are indicated in FIG. 6 by circle segments of varying length.

[0099] The control unit 44 includes a processor or the like for executing program code to generate the maintenance program. The generated maintenance program can be executed by the control unit 44, as basically described above, generating and implementing corresponding control commands for operating the maintenance system 2 for this purpose.

[0100] As indicated above, the maintenance system 1 is equipped with a human-machine interface 54 adapted to display maintenance information and further to acquire input data that may be entered by an operator not shown.

[0101] A wireless interface 97 is provided on the bioreactor 2 for transmitting data, in particular, for sending reactor characteristics data and/or for receiving updates or control data. The wireless interface 97 can be used in addition or alternatively to the interface 95.

[0102] FIG. 6 further schematically shows a central server 100 with a wireless interface 101 so that wireless communication links can be established between the server 100, the maintenance system 1, and the bioreactor 2. Instead of the central server 100, a mobile operating device with the same functionality may also be provided (not shown).

[0103] With reference to FIG. 7, embodiments of a method for generating a maintenance program used to operate the maintenance system 1 on the bioreactor 2 are described below.

[0104] First, the method is described in a first embodiment. In step S50, reactor characteristics data stored at the bioreactor 2 are transmitted from the bioreactor 2 to the maintenance system 1 via the interface 95 and received there at the interface 96. In an optional step S51, maintenance characteristics data is transmitted to the maintenance system 1 via the same transmission path. The maintenance characteristics data preferably comprises information about maintenance of the bioreactor 2 carried out in the past. In step S52, system characteristics data stored at the maintenance system 2, e.g., in the memory of the control unit 44, is acquired. In step S53, the control unit 44 generates a maintenance program based on the acquired reactor characteristics data, the system characteristics data and the optionally acquired maintenance characteristics data. In step 54, the maintenance program can be executed by the control unit 44, cf. FIG. 2, to maintain the bioreactor 1. During the described process steps, parts of the reactor characteristics data, the system characteristics data or the maintenance characteristics data can be acquired at the human-machine interface 54. Furthermore, the process sequence can be monitored and controlled via the human-machine interface 54.

[0105] In the following, the method is described with reference to FIG. 7 in a second embodiment. In step S50, reactor characteristics data is transmitted from the bioreactor 2 to the central server 100 via the interface 97. In an optional step S51, maintenance characteristics data is transmitted to the central server 100 via the same transmission path. Preferably, the maintenance characteristics data comprises information about maintenance of the bioreactor 2 performed in the past. In step S52, system characteristics data, which is stored at the maintenance system 1, e.g., in the memory of the control unit 44, are acquired and transmitted to the central server 100 via the interfaces 98 and 101. In step S53, the central server 100 generates a maintenance program based on the acquired reactor characteristics data, the system characteristics data, and the optionally acquired maintenance characteristics data. The generated maintenance program is then transmitted to the maintenance system 1 via the interfaces 101 and 98. As required, the maintenance program can then be executed by the control unit 44 to maintain the bioreactor 2 (step S54). During the described process steps, portions of the reactor characteristics data, the system characteristics data, or the maintenance characteristics data may be acquired at the human-machine interface 54. Furthermore, the process sequence can be monitored and controlled via the human-machine interface 54.

[0106] Said interfaces 95, 96, 97, and 98 need not all be formed on the bioreactor 2 or the maintenance system 1. Rather, it is possible that only those interfaces are present that are required in the context of one of the described embodiments.