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Related Concept Videos

Control Systems01:10

Control Systems

962
Control systems are everywhere in contemporary society, influencing diverse applications from aerospace to automated manufacturing. These systems can be found naturally within biological processes, such as blood sugar regulation and heart rate adjustment in response to stress, as well as in man-made systems like elevators and automated vehicles. A control system is essentially a network of subsystems and processes that collaboratively convert specific inputs into desired outputs.
At the heart...
962
Control Systems: Applications01:25

Control Systems: Applications

524
Electrical engineering plays a pivotal role in our daily lives, with control systems at the heart of many applications, from home appliances to sophisticated space shuttles. Control systems manage and regulate the behavior of devices and processes, ensuring they function safely, correctly, and efficiently.
In modern vehicles, control systems manage various functions to enhance performance and safety. The steering wheel and accelerator are primary inputs in a car's control system. The...
524
Open and closed-loop control systems01:17

Open and closed-loop control systems

567
Control systems are foundational elements in automation and engineering. They are broadly categorized into open-loop and closed-loop systems. These classifications hinge on the presence or absence of feedback mechanisms, significantly influencing the system's performance, complexity, and application.
An open-loop control system operates without feedback from the output. It consists of two primary elements: the controller and the controlled process. The controller receives an input signal...
567
Feedback control systems01:26

Feedback control systems

256
Feedback control systems are categorized in various ways based on their design, analysis, and signal types.
Linear feedback systems are theoretical models that simplify analysis and design. These systems operate under the principle that their output is directly proportional to their input within certain ranges. For instance, an amplifier in a control system behaves linearly as long as the input signal remains within a specific range. However, most physical systems exhibit inherent nonlinearity...
256
Electro-mechanical Systems01:19

Electro-mechanical Systems

876
Electromechanical systems are intricate configurations that effectively combine electrical and mechanical elements to achieve a desired outcome. Central to many of these systems is the DC motor, a device that converts electrical energy into mechanical motion, enabling various applications ranging from simple fans to complex robotic mechanisms.
A key component of the DC motor is the armature, a rotating circuit positioned within a magnetic field. As an electric current passes through the...
876
Controller Configurations01:22

Controller Configurations

72
Controller configurations are crucial in a car's cruise control system because they manage speed over time to maintain a consistent pace regardless of road conditions, thereby meeting design goals. In traditional control systems, fixed-configuration design involves predetermined controller placement. System performance modifications are known as compensation.
Control-system compensation involves various configurations, most commonly series or cascade compensation, in which the controller...
72

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Operation of the Collaborative Composite Manufacturing CCM System
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A universal digital control concept for end-to-end manufacturing.

L Kuchler1, A Azimi2, H Damiri3

  • 1Research Center Pharmaceutical Engineering GmbH, Inffeldgasse 13, 8010 Graz, Austria.

International Journal of Pharmaceutics
|April 16, 2025
PubMed
Summary

Advanced manufacturing requires real-time process control. This study introduces a flexible control concept using a digital twin and soft sensors for complex pharmaceutical production, ensuring quality in high-speed operations.

Keywords:
Advanced process controlControl conceptEnd-to-end manufacturingReal-time monitoring

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Area of Science:

  • Pharmaceutical manufacturing
  • Process control engineering
  • Advanced manufacturing systems

Background:

  • Modern pharmaceutical manufacturing faces increased complexity with advanced concepts like continuous processing and modular design.
  • Traditional quality control methods are insufficient for high-speed manufacturing, necessitating real-time monitoring and control.
  • Existing control strategies often lack the flexibility to adapt to diverse processing, equipment, and automation setups.

Purpose of the Study:

  • To present a universally applicable control concept for complex manufacturing processes.
  • To demonstrate a flexible control strategy adaptable to batch and continuous operations, manual and automated systems, and varying equipment scales.
  • To validate the control concept in a real-world end-to-end pharmaceutical manufacturing line.

Main Methods:

  • Development of a universally applicable control concept integrating batch and continuous processes.
  • Implementation of a compact, end-to-end tablet manufacturing line including API synthesis, crystallization, filtration, washing, and formulation.
  • Utilization of a control strategy combining Process Analytical Technology (PAT) sensors, equipment data, and soft sensors, integrated with a digital twin for model-based control.

Main Results:

  • Successful demonstration of the control concept on a pharmaceutical manufacturing line.
  • Effective monitoring and control of product quality using soft sensors and feeder data.
  • Integration of process and quality information into a digital twin for executing model-based control strategies.

Conclusions:

  • The presented control concept offers a high level of control and flexibility for complex manufacturing environments.
  • The digital twin approach, combined with diverse data sources, enables robust real-time process and quality management.
  • This strategy is suitable for advanced pharmaceutical manufacturing, addressing the limitations of traditional control methods.