U.S. patent application number 15/017077 was filed with the patent office on 2016-06-02 for programmable logic controller-based control center and user interface for air sampling in controlled environments.
The applicant listed for this patent is Veltek Associates, Inc.. Invention is credited to JEFFREY CHURCHVARA, Mark A. Phillips.
Application Number | 20160153948 15/017077 |
Document ID | / |
Family ID | 50681176 |
Filed Date | 2016-06-02 |
United States Patent
Application |
20160153948 |
Kind Code |
A1 |
CHURCHVARA; JEFFREY ; et
al. |
June 2, 2016 |
PROGRAMMABLE LOGIC CONTROLLER-BASED CONTROL CENTER AND USER
INTERFACE FOR AIR SAMPLING IN CONTROLLED ENVIRONMENTS
Abstract
In accordance with an aspect of the present invention there is
provided a system for sampling air at multiple locations in a
controlled environment. The system includes one or more air
sampling devices configured to monitor and test a volume of air
within a controlled environment. A control center including a
programmable logic controller (PLC) is configured to monitor and
control the one or more air sampling devices. One or more touch
panel displays are connected to the control center and provide a
human-computer interface between the control center and users.
Inventors: |
CHURCHVARA; JEFFREY;
(Downingtown, PA) ; Phillips; Mark A.; (King of
Prussia, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Veltek Associates, Inc. |
Malvern |
PA |
US |
|
|
Family ID: |
50681176 |
Appl. No.: |
15/017077 |
Filed: |
February 5, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13673523 |
Nov 9, 2012 |
9285792 |
|
|
15017077 |
|
|
|
|
Current U.S.
Class: |
700/282 |
Current CPC
Class: |
G01N 1/2273 20130101;
G01N 33/0073 20130101; G08B 25/009 20130101; G05B 19/058 20130101;
G01N 33/0063 20130101; G05B 2219/13031 20130101; G08B 21/12
20130101; G01M 3/2815 20130101; G05B 19/02 20130101; G08B 25/14
20130101 |
International
Class: |
G01N 33/00 20060101
G01N033/00; G01N 1/22 20060101 G01N001/22; G05B 19/05 20060101
G05B019/05 |
Claims
1.-28. (canceled)
29. A method for sampling air at multiple locations, comprising
steps of: drawing in a respective volume of air through one or more
air sampling devices; monitoring an air sampling of each of the one
or more air sampling devices using a control center including a
programmable logic controller (PLC); and transmitting indications
of the air sampling by each of the one or more air sampling devices
to one or more touch panel displays.
30. The method of claim 29, further comprising steps of: detecting
an alarm at one of the one or more air sampling devices; and
transmitting an indication of the alarm to the one or more touch
panel displays.
31. The method of claim 29, further comprising steps of: detecting
an alarm at one of the one or more air sampling devices when a rate
of air flow through the one of the one or more air sampling devices
deviates from a desired value by a predetermined amount; and
transmitting an indication of the alarm to the one or more touch
panel displays.
32. The method of claim 29, further comprising steps of: monitoring
a flow rate of air through each of one or more ports coupled
respectively to the one or more air sampling devices; detecting a
flow rate error through one of the one or more ports; and
transmitting an indication of the flow rate error to the one or
more touch panel displays.
33. The method of claim 29, further comprising steps of: receiving
a command from one of the one or more touch panel displays for
controlling air flow through one of the one or more air sampling
devices; and controlling the air flow through the one of the one or
more air sampling devices via a vacuum line connected to the one of
the one or more air sampling devices.
34. The method of claim 33, further comprising a step of
transmitting to each of the one or more touch panel displays data
regarding a flow rate of air through the one or the one or more air
sampling devices for being displayed in each of the one or more
touch panel displays.
35. The method of claim 29, further comprising steps of: receiving
a command from one of the one or more touch panel displays for
controlling air flow through one of the one or more air sampling
devices; and controlling a flow rate of air through a port coupled
to the one of the one or more touch panel displays via a vacuum
line.
36. The method of claim 29, wherein the one or more touch panel
displays are co-located with the one or more air sampling
devices.
37. The method of claim 29, wherein the one or more touch panel
displays are located inside a clean room environment.
38. A method for sampling air at multiple locations, comprising
steps of: drawing in a respective volume of air through one or more
air sampling devices; monitoring an air sampling of each of the one
or more air sampling devices using a control center including a
programmable logic controller (PLC); and providing one or more
touch panel displays connected to the control center for providing
a human-computer interface between the control center and
users.
39. The method of claim 38, further comprising a step of
automatically activating an alarm at one or more of the one or more
touch panels when a rate of air flow through one or more of the one
or more air sampling devices deviates from a desired value by a
predetermined amount.
40. The method of claim 39, further comprising a step of
automatically activating an alarm at a first one of the one or more
touch panels when a rate of air flow through a first one of the one
or more air sampling devices deviates from a desired value by the
predetermined amount.
41. The method of claim 38, further comprising steps of: receiving,
in each of the one or more touch panel displays, data from the
control center regarding the one or more air sampling devices; and
displaying, in each of the one or more touch panel displays, the
received data.
42. The method of claim 38, further comprising a step of
controlling at least one of the one or more air sampling devices
from the one or more touch panels.
43. The method of claim 38, further comprising a step of
controlling the one or more air sampling devices using the control
center.
44. The method of claim 38, further comprising a step of activating
an alarm when a predetermined alarm condition has been
satisfied.
45. The method of claim 44, wherein the predetermined alarm
condition includes when the actual rate of air flow at the one or
more air sampling devices deviates a predetermined amount from a
desired rate of air flow.
46. The method of claim 38, wherein the one or more touch panel
displays are co-located with the one or more air sampling
devices.
47. The method of claim 38, wherein the one or more touch panel
displays are located inside a clean room environment.
48. A method for sampling air at multiple locations, comprising
steps of: drawing in a respective volume of air through one or more
air sampling devices; controlling an air sampling of each of the
one or more air sampling devices using a control center including a
programmable logic controller (PLC); and providing one or more
touch panel displays connected to the control center for providing
a human-computer interface between the control center and
users.
49. The method of claim 48, further comprising a step of
automatically activating an alarm at one or more of the one or more
touch panels when a rate of air flow through one or more of the one
or more air sampling devices deviates from a desired value by a
predetermined amount.
50. The method of claim 49, further comprising a step of
automatically activating an alarm at a first one of the one or more
touch panels when a rate of air flow through a first one of the one
or more air sampling devices deviates from a desired value by the
predetermined amount.
51. The method of claim 48, further comprising steps of: receiving,
in each of the one or to more touch panel displays, data from the
control center regarding the one or more air sampling devices; and
displaying, in each of the one or more touch panel displays, the
received data.
52. The method of claim 48, further comprising a step of
controlling at least one of the one or more air sampling devices
from the one or more touch panels.
53. The method of claim 48, further comprising a step of monitoring
the one or more air sampling devices by the control center.
54. The method of claim 38, ter comprising, a step of activating an
alarm when a predetermined alarm condition has been satisfied.
55. The method of claim 54, wherein the predetermined arm condition
includes when the actual rate of air flow at the one or more air
sampling devices deviates a predetermined amount from a desired
rate of air flow.
56. The method of claim 48, wherein the one or more touch pane
displays are co-located with the one or more air sampling
devices.
57. The method of claim 48, wherein the one or more touch panel
displays are located inside a clean room environment.
Description
FIELD OF INVENTION
[0001] The present invention relates to devices and methods for
monitoring airborne contaminants. In particular, the present
invention relates to a programmable logic controller-based control
center and corresponding human computer interface for controlling
air sampling in controlled environments.
BACKGROUND OF THE INVENTION
[0002] Clean rooms found in manufacturing, research, and other
facilities are typically classified into two broad categories based
on the static air pressure inside the rooms relative to atmospheric
pressure and/or based on the air pressure in spaces adjacent the
clean rooms. A positive air pressure room is maintained at an
absolute air pressure greater than atmospheric pressure, greater
than the air pressure in spaces adjacent the clean room, or both.
The positive air pressure in such rooms is provided by pumping
filtered and/or conditioned air into the rooms and controlling the
flow of air out of the rooms. The adjacent spaces, which may be
manufacturing facilities or offices, are typically maintained at or
close to atmospheric pressure by heating, ventilation, and air
conditioning (HVAC) systems, or by providing an opening to the
environment that allows the adjacent spaces to equilibrate with
atmospheric pressure. Thus, air flowing from the positive pressure
clean room will flow toward the lower pressure in adjacent rooms or
to the atmosphere.
[0003] When a positive air pressure clean room is breached, air
flowing to adjacent spaces or the atmosphere is generally not a
problem as long as airborne contaminants present in the clean room
do not pose a potential adverse health effect to people in the
adjacent spaces. Typically, the air inside clean rooms in which
electronics, aerospace hardware, optical systems, military
equipment, and defense-related research are manufactured or
conducted may not contain airborne gases, vapors, and particulate
matter at concentrations that present a safety or health concern to
human health or the environment. However, that is not always the
case, as other operations within those industries may generate
contaminants that are above acceptable levels and, therefore, must
be prevented from escaping the clean room without treatment.
[0004] A negative air pressure room is maintained at an absolute
air pressure that is either less than atmospheric pressure, less
than the air pressure in spaces adjacent the clean room, or both.
The negative pressure is maintained by pumping air out of the room
at a rate faster than that at which filtered and/or conditioned air
is pumped into the room. Negative pressure rooms are often used
when there is a concern that contaminants in the air in the room
may pose a potential health threat to human health in adjacent
spaces or the environment.
[0005] Notwithstanding the human health and environmental
implications, certain types of manufacturing and research
operations must be conducted within a positive air pressure clean
room to satisfy regulatory requirements and industry-adopted good
manufacturing and laboratory quality control standards. For
example, state and federal regulations, including those promulgated
by the National Institute for Occupational Safety and Health
(NIOSH), may necessitate the use of positive or negative pressure
clean rooms.
[0006] In particular, the U.S. Food & Drug Administration (FDA)
requires that pharmaceutical production be performed within the
confines of clean rooms that provide for the validation and
certification that manufactured batches of pharmaceutical products
are being produced in a sanitary environment. Various FDA
regulations and standards also specify requirements for air
sampling and/or air monitoring equipment to be used inside clean
rooms to verify or validate the cleanliness of the facility during
certain drug manufacturing activities. The regulations also provide
for electronic data recording, accuracy, precision, and
record-keeping relating to monitoring the air quality within clean
rooms. Similar requirements are imposed on other industries, such
as the biotechnology industry.
[0007] Current systems for testing and monitoring the air quality
in controlled environments include a plurality of sterlizable
microbial atriums (SMA) that are connected to a distributed digital
control (DDC) control center. An example of an SMA-DDC system
includes the SMA-DDC-10 and integrated One Touch Control System
produced by Veltek Associates Inc. of Malvern, Pa. Other systems
are shown in U.S. Pat. Nos. 8,169,330; 7,973,668; 7,940,188; and
8,188,874, the disclosures of which are hereby incorporated by
reference. Such systems typically include a hardware-based
interface that allows users to interface with the air sampling
equipment.
[0008] A disadvantage associated with conventional air sampling
systems is that, because the HCI is hardware-based, it is often
difficult and expensive to customize or change. For example, it may
be difficult or expensive for a user to increase or decrease the
number of monitoring locations based on changes to the user's needs
Accordingly, a need exists for a system for controlling air
sampling in controlled environments that is flexible, cheaper to
implement feature changes, and provides a consistent user
interface.
SUMMARY OF THE INVENTION
[0009] In accordance with an aspect of the present invention there
is provided a system for sampling air at multiple locations in a
controlled environment. The system includes one or more air
sampling devices configured to monitor and test a volume of air
within a controlled environment. A control center including a
programmable logic controller (PLC) is configured to monitor and
control the one or more air sampling devices. One or more touch
panel displays are connected to the control center and provide a
human-computer interface between the control center and users.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For the purpose of illustration, there are shown in the
drawings certain embodiments of the present invention. In the
drawings, like numerals indicate like elements throughout. It
should be understood that the invention is not limited to the
precise arrangements, dimensions, and instruments shown. In the
drawings:
[0011] FIG. 1 is a schematic diagram of an exemplary facility
having a clean room therein, in accordance with an exemplary
embodiment of the present invention;
[0012] FIG. 2 is a schematic diagram of a tracking/logging and air
sampling/monitoring system for use in the clean room of FIG. 1 that
includes a PLC-based control center and one or more associated
touch panel displays, in accordance with an exemplary embodiment of
the present invention; and
[0013] FIG. 3 is a screenshot of an exemplary human computer
interface that may be displayed on a touch panel display for
monitoring or controlling one or more air sampling devices via the
control center, in accordance with an exemplary embodiment of the
present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] None of the conventional devices described above provide a
high degree of flexibility to rearrange a display to show any
number of individual parameters associated with air sampling and
monitoring including, but not limited to, the location name, sample
time, or duration of air quality tests. Because these conventional
devices are not programmable, as new features are created, physical
changes to the hardware are required. Additionally, none of the
conventional devices described above allow for the collection of
time sample data. The present invention overcomes these
shortcomings by providing a flexible, programmable air sampling and
monitoring system that includes a programmable logic
controller-based control center and a plurality of associated touch
panel displays sharing a unified interface.
[0015] The present invention will be explained in terms of
exemplary embodiments. This specification discloses one or more
embodiments that incorporate the features of this invention. The
disclosure herein will provide examples of embodiments, including
examples of data analysis from which those skilled in the art will
appreciate various novel approaches and features developed by the
inventors. These various novel approaches and features, as they may
appear herein, may be used individually, or in combination with
each other as desired.
[0016] In particular, the embodiment(s) described, and references
in the specification to "one embodiment", "an embodiment", "an
example embodiment", etc., indicate that the embodiment(s)
described may include a particular feature, structure, or
characteristic, but every embodiment may not necessarily include
the particular feature, structure, or characteristic. Moreover,
such phrases are not necessarily referring to the same embodiment.
Further, when a particular feature, structure, or characteristic is
described in connection with an embodiment, persons skilled in the
art may affect such feature, structure, or characteristic in
connection with other embodiments whether or not explicitly
described.
[0017] Embodiments of the invention may be implemented in hardware,
firmware, software, or any combination thereof, or may be
implemented without automated computing equipment. Embodiments of
the invention may also be implemented as instructions stored on a
machine-readable medium, which may be read and executed by one or
more processors. A machine-readable medium may include any
mechanism for storing or transmitting information in a form
readable by a machine (e.g. a computing device). For example, a
machine-readable medium may include read only memory (ROM); random
access memory (RAM); hardware memory in PDAs, mobile telephones,
and other portable devices; magnetic disk storage media; optical
storage media; flash memory devices; electrical, optical,
acoustical, or other forms of propagated signals (e.g. carrier
waves, infrared signals, digital signals, analog signals, etc.),
and others. Further, firmware, software, routines, instructions,
may be described herein as performing certain actions. However, it
should be appreciated that such descriptions are merely for
convenience and that such actions in fact result from computing
devices, processors, controllers or other devices executing the
firmware, software, routines, instructions, etc.
[0018] The present invention will be described in terms of one or
more examples, with reference to the accompanying drawings. In the
drawings, like reference numbers indicate identical or functionally
similar elements. Additionally, the left-most digit(s) of most
reference numbers may identify the drawing in which the reference
numbers first appear. Several exemplary embodiments of the
invention are described for illustrative purposes, it being
understood that the invention may be embodied in other forms not
specifically shown in the drawings.
[0019] Turning first to FIG. 1, shown therein is a schematic of an
exemplary facility 100 having one or more clean rooms 102 therein,
in accordance with an exemplary embodiment of the present
invention. The clean room 102 is surrounded by an adjacent space
104 and the outdoor atmosphere 106. The adjacent space 104 may be
one or more rooms within the same facility 100 in which the clean
room 102 is located and that adjoin the clean room 102, such as,
for example, a separate manufacturing room, another clean room, a
finish and fill room, a research laboratory, offices, etc. The
clean room 102 and adjacent space 104 are separated by a divider,
such as a wall 105.
[0020] The clean room 102 in the exemplary facility 100 is capable
of being maintained at an air pressure P.sub.1 that is less than or
greater than the air pressure P.sub.2 of the adjacent space 104 and
atmospheric air pressure P.sub.ATM of the outdoor atmosphere 106.
That is accomplished by an HVAC system (not shown) that causes
conditioned and filtered air to be pumped into the clean room 102
at a controlled flow rate Q.sub.IN as depicted in FIG. 1. Air
inside the clean room 102 that is pumped out of or otherwise flows
out of the clean room 102 is represented by Q.sub.OUT. When the
difference between Q.sub.IN and Q.sub.OUT (i.e.,
Q.sub.IN-Q.sub.OUT) is greater than zero, a positive pressure will
be maintained in the clean room 102. And, when the difference
between Q.sub.IN and Q.sub.OUT is less than zero, a negative
pressure will be maintained in the clean room 102.
[0021] Turning now to FIG. 2, shown therein is a schematic diagram
of an air sampling/monitoring system 200, in accordance with an
exemplary embodiment of the present invention. The system 200
generally includes a control center 210, air sampling devices 260,
and user interfaces or touch panels 270. The control center 210 and
the touch panels 270 can include processors, displays, wireless
devices, and memory to operate in accordance with the invention.
The touch panels 270 can be wall-mounted, desktop, portable, or a
combination.
[0022] The system 200 is configured for use in tracking and logging
data obtained from a plurality of air sampling devices. During air
sampling, air from the clean room 102 is drawn through the air
sampling devices 260a-d of the system 200 to collect contaminants
present in the air of the clean room 102. An air sampling device
260 is shown, for instance, in U.S. Publication No. 2011/0167931,
the content of which is hereby incorporated by reference. The data
acquired about the air sampling devices 260a-d is used to monitor
and gather airborne particle count and other parameter levels in
the clean room 102 in order to maintain the integrity of
experiments or production processes therein.
[0023] The system 200 includes a control center 210, which may be
located in the adjacent space 104 or adjacent to or remote from
(i.e., not directly adjacent to) the clean room 102. The control
center 210 may include modular ports, such as the modular ports
described and illustrated in the '330 patent, where each of such
ports may be connected to a vacuum air line. Using these ports, the
control center 210 can be configured to draw in air from the air
sampling devices 260a-260d and to provide for the air sampling
performed by the air sampling devices 260a-260d. The vacuum air
lines may be connected across the wall 105 via a wall-mounted quick
disconnect outlet, where the outlets and are located on the wall
105 in between the clean room 102 and the adjacent space 104.
[0024] The system 200 further includes a plurality of air sampling
devices 260a, 260b, 260c, and 260d, all of which may be co-located
together in the clean room 102. In the exemplary embodiment of the
system 200 illustrated in FIG. 2 and described herein, the system
200 comprises four air sampling devices 260a-260d. It is to be
understood that the number of air sampling devices 260a-260d is not
limited by the system 200 to any particular quantity of air
sampling devices 260. That is, the system 200 is scalable to
substantially any number, n, of air sampling devices 260. The air
sampling devices 260a-260d may be any known air sampling device for
collecting a volume of air. An example of an air sampling device
suitable for use as the air sampling devices 260 is described in
the '330 patent, the contents of which are incorporated herein by
reference.
[0025] The system 200 further includes subjects 265a, 265b, 265c,
and 265d, which are located at various sites within the clean room
102. The air sampling devices 260a-260d are positioned to collect
airborne contaminants in the clean room 102, and can be positioned,
for instance, adjacent to one or more of the subjects 265a-265d,
where the subjects 265 can be equipment, personnel, etc.
Specifically, the air sampling devices 260a-260d can be used to
collect the air surrounding respective subjects 265a-265d, i.e., to
draw air over the subjects 265a-265d during air sampling, so that
contaminants in the air of the clean room 102 at sites of interest
are collected by the air sampling devices 260a-d.
[0026] The control center 210 may connect to a vacuum pump (not
shown), additional vacuum air lines (not shown), or other
equipment, illustration of which is omitted herein for clarity. The
control center 210 is used to turn on the air flow to each air
sampling device 260a-260d so that any combination of the air
sampling devices 260a-260d can be employed simultaneously to
perform sampling cycles at various locations throughout the clean
room 102. In one exemplary embodiment, the control center 210 is
configured so that each air sampling device 260a-260d processes 1
CFM (28.3 liters/min) of air, which is the desired air flow rate
needed to conduct a proper sampling cycle.
[0027] In another exemplary embodiment, the control center 210 is
configured to allow for the air flow rates to be individually set,
as described below. The control center 210 communicates data and
commands from the touch panels 270 and the air sampling devices
260a-260d. The control center 210 is connected to each of the air
sampling devices 260a-260d via respective vacuum connections 232a,
232b, 232c, and 232d. The vacuum connections 232a and 232b are
connected across the wall 105 via a connector 114A, and the vacuum
connections 232c and 232d are connected across the wall 105 via a
connector 114B.
[0028] It is to be understood, however, that the control center
210, the touch panels 270, and the air sampling devices 260a-260d
communicate with one another in any suitable manner. For example,
in an exemplary alternative embodiment, the touch panels 270 have
network addresses, and the control center 210 communicates with the
different touch panels 270 by use of those network addresses via a
common connection (e.g. an Ethernet network or wireless local area
network (LAN)).
[0029] The exemplary embodiment of the system 200 illustrated in
FIG. 2 illustrates four vacuum connections 232a-232d, each of which
corresponds to a respective one of the air sampling devices
260a-260d. It is to be understood that the number of vacuum
connections 232a-232d is not limited by the system 200 to any
particular quantity of connections. That is, the system 200 is
linearly scalable to substantially any number, n, of vacuum
connections 232a-232n. Furthermore, although the control center 210
and the touch panels 270 are shown in wired communication with one
another, it is to be appreciated that these components of the
system 200 may communicate wirelessly in an alternative exemplary
embodiment of the system 200.
[0030] The control center 210 includes interfaces for interfacing
with the touch panels 270a-d, and the control center 210 includes
interfaces for interfacing with the air sampling devices 260a-260d.
The control center 210 detects conditions (e.g., flow rates, alarm
conditions, etc.) and issues commands (e.g., to start and/or stop
air flow) with the air sampling devices 260a-260d via respective
vacuum connections 232a-232d. The control center 210 also receives
data and commands from the touch panels 270a-270d over respective
connections 275 and 285. Various examples of data and commands
transmitted by the touch panels 270a-d, the air sampling devices
260a-d, and the control center 210 are described below.
[0031] In one exemplary scenario, a first touch panel such as touch
panel 270a may be located near a first air sampling device such as
air sampling device 260a and away from a second air sampling device
such as air sampling device 260b. By interacting with the interface
presented by the first touch panel 270a, the user may cause a
signal to be sent to the control center 210 for thereby controlling
or monitoring the second air sampling device 260b. Thus, any air
sampling device 260a-d may be controlled or monitored using any
touch panel 270a-d irrespective of where they are located.
[0032] In another exemplary scenario, an alarm may be generated by
a first air sampling device 260a and a notification of the alarm
may be presented to one or more of the touch panels 270a-d
irrespective of their locations. For example, in the exemplary
configuration shown in FIG. 2, an alarm generated by the air
sampling device 260a may be detected by the control center 210 and
then information associated with the alarm may be relayed to one or
more of the remotely-located touch panels 270b-d, instead of or in
addition to the adjacent touch panel 270a. In this way, important
alarm information may be automatically presented to the location(s)
where users are located when the alarm is detected rather than
being presented only at the location of the alarm, where users may
or may not be located. It will be recognized, however, that the
touch panels 270 can directly communicate with one another, such as
to de-activate an alarm signal.
[0033] As mentioned above, the present invention overcomes the
shortcomings of conventional air monitoring systems having
hardwired components by providing a more flexible and programmable
air sampling and monitoring system that includes a programmable
logic controller-based control center and a plurality of associated
touch panel displays sharing a unified interface. The programmable
logic controller (PLC) is a digital computer used for automation of
electromechanical processes, including control of machinery, such
as the sterilizable microbial atriums (SMAs) described herein.
Unlike general-purpose computers, the PLC is designed for multiple
inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and
impact. The PLC can be programmed using application software
executed on separate general purpose computers. Such a computer may
be connected to the PLC through Ethernet, RS-232, RS-485, RS-422,
or other suitable communications cabling. Generally, the
programming software provides functions for debugging and
troubleshooting the PLC software, for example, by highlighting
portions of the logic to show current status during operation or
via simulation. The software can upload and download the PLC
program for backup and restoration purposes. In some PLC
embodiments, the program is transferred from a personal computer to
the PLC through a programming board which writes the program into a
removable chip such as an EEPROM or EPROM. PLCs may be used to
interact with users for the purpose of configuration, alarm
reporting or everyday control. A human-machine interface (HMI) is
employed for this purpose. HMIs are also referred to as a
human-computer interface (HCI), a man-machine interface (MMI) and a
graphical user interface (GUI). A simple system may use buttons and
lights to interact with the user. Text displays are available as
well as graphical touch screens.
[0034] The control center 210 may communicate data and commands
provided by the touch panels 270 and the air sampling devices
260a-260d for tracking and monitoring the system 200 in real time
and logging the data and commands in a database 290 maintained by
the control center 210. Although the system 200 is described and
illustrated herein as including the database 290, it is to be
understood that the system 200 is not so limited. In other
exemplary embodiments, the element 290 is a spreadsheet, a flat
text file, or other data structure stored in a computer-readable
medium.
[0035] The air sampling devices 260a-260d are configured to
independently monitor various data during operation, e.g., during
air sampling. Such data include any flow rates sensed by the
respective air sampling devices 260a-260d, alarm signals generated
by the respective touch panels 270, etc. For example, the touch
panels 270 monitor and display the actual flow rate that is
realized at their respective air sampling devices 260a-260d. If the
flow rate is off by +/-0.5% (i.e., not within the range of
0.95-1.05 CFM or 26.9-29.7 liters/min), then the corresponding air
sampling device 260a-260d may generate an alarm signal.
[0036] An additional aspect of this exemplary embodiment provides
that the control center 210 communicates any data and alarm signals
received from the touch panel 270 to one or more of the other touch
panels 270, so that they may activate their respective visual alert
indicators and audible alarms. The data and alarm signals can be
independently monitored and controlled by the control center
210.
[0037] In one embodiment, when a low flow rate is detected in one
of the air sampling devices 260a-260d, such as when a detected flow
rate falls below 1 CFM or any other suitable and configurable
threshold value, the control center 210 may provide one or more
types of alarms for alerting a user of the low flow condition. For
example, lights or sounds may be activated including strobe lights,
colored lights, sirens, and pre-recorded audio files. Additionally
or alternatively, with the PLC-based control center 210, an
escalation protocol may be implemented whereby a predefined
sequence of steps may be taken in response to the failure of a user
to address/stop the alarm within predefined time period(s). For
example, immediately after an initial alarm condition has been
triggered, a visual map of the location of the low flow may be
shown and/or highlighted within the context of the facility. If the
alarm should continue without user acknowledgement (ACK), the next
step in the escalation protocol may be performed. If after five
minutes no ACK is received, an email may be sent to an
administrator or other designated user(s). If after ten minutes no
ACK is received, an email may be sent to an expanded list of
users/administrators. If after fifteen minutes no ACK is received,
a simple message service (SMS) text message may be sent to one or
more users. If after twenty minutes no ACK is received, a phone
call may automatically be placed to one or more users and a
designated pre-recorded sound file may be played. If still no ACK
is received, a message may be sent to a different user or set of
users located remotely from the facility who are dedicated to
responding to such alarms.
[0038] During operation, the control center 210 also monitors data
relating to air sampling. For example, the control center 210
monitors flow rates through the ports of the control center 210,
whether the individual ports of the control center 210 are powered
up, and whether the ports are in an air sampling mode and/or are
experiencing an air flow error during an air sampling cycle. The
control center 210 may transmit any such data to the touch panels
270.
[0039] Thus, as depicted in FIG. 2, the system 200 further includes
one or more touch panels 270, which are connected to the control
center 210 via a wired or wireless connection 275, 285. The touch
panel 270 may be co-located with the air sampling devices 260a-260d
in the clean room 102, as shown in FIG. 2, or co-located with the
control center 210, or otherwise located outside of the clean room
102. Thus, although the touch panels 270 are each preferably
located proximal to a respective air sampling device 260, they need
not be. Rather, the touch panels 270 can be located remote from all
of the air sampling devices 260.
[0040] The touch panel 270 includes an interface for communicating
with the control center 210 for receiving data from the control
center 210 and providing commands to the control center 210 for
relaying to their proper destinations. It is to be understood that
the touch panel 270 may be configured to receive any data and
commands provided to the control center 210 described herein.
[0041] For example, when the control center 210 and the touch panel
270 communicate, the touch panel 270 may receive data from the
control center 210 collected during an air sampling period. As
described above, such data may indicate whether the individual
ports of the control center 210 are powered up, are in an air
sampling mode, and/or experience an air flow error during an air
sampling cycle. In that way, the touch panel 270 can detect the
state of activity of each of the individual ports of the control
center 210, thereby allowing a user to determine where in the
facility 100 air sampling is being conducted (i.e., which air
sampling devices 260a-260d are presently being operated, the time
associated with a sampling cycle, etc.) and at which air sampling
devices 260a-260d any errors occur. Such data may further indicate
the flow rates sensed in the air sampling devices 260a-260d, alarm
conditions in the air sampling devices 260a-260d, etc. Thus, the
touch panel 270 may be used to display data, e.g., data collected
during an air sampling period or other data described below, in
real time regarding components of the system 200.
[0042] The touch panel 270 may also be configured to provide
commands to components of the system 200, such as the air sampling
devices 260a-260d and the control center 210. For example, the
touch panel 270 can also be used to remotely start and stop
sampling at various air sampling devices 260a-260d within the
facility 100, thereby eliminating the need for the user to access
the control center 210 to perform these functions. Thus, in an
exemplary embodiment, the touch panel 270 includes various input
means, such as a touch screen that receives input from a user to
signal to the control center 210 which air sampling devices
260a-260d to operate. The touch panel 270 communicates such
commands to the control center 210, thereby eliminating the need
for the user to leave the location (room) of the touch panel 270 to
operate the control center 210 or the air sampling devices
260a-260d.
[0043] In an exemplary embodiment, the control center 210 monitors
conditions in the clean room 102 and may monitor conditions in
other rooms, e.g., other clean rooms 102 or rooms 104. The control
center 210 includes software that includes a graphical
representation of the different components of the system 200. The
control center 210 and/or the touch panels 270 may include software
to render such representations, receive real-time data from the
control center 210 for these components, and display the real-time
data.
[0044] The control center 210 may also be configured to collect and
store data regarding the operation of the components of the system
200 and commands provided by components of the system 200. Data
recorded by the control center 210 may include data obtained during
an air sampling period (the period of time over which the subjects
265a-265d collect airborne contaminants from a clean room, such as
the clean room 102) and data obtained during an incubation period.
Such data may include data scanned by a barcode scanner, data
inputted by a user, and data monitored by the air sampling devices
260a-260d and the control center 210. The control center 210 stores
data and commands in the database 290 or other memory.
[0045] Data obtained during an air sampling period may include any
of the following data: (1) identification data of the subjects
265a-265d; (2) location data of the subjects 265a-265d; (3) the
date and time such location data was obtained; (4) identification
data of the user; and (5) the date and, optionally, time the
subjects 265a-265d expire. Data obtained during the air sampling
period may also include any of the following monitored data: (1)
the flow rate at each individual air sampling device 260a-260d; (2)
the dates and times of the measured flow rates; (3) flow
alerts/alarms generated at the air sampling devices 260a-260d; (4)
indications of whether the individual ports of the control center
210 are powered up; (5) indications of whether the individual ports
of the control center 210 are in an air sampling mode; (6) air flow
errors detected by the control center 210; (7) flow rates detected
by the control center 210; (8) identification data of the air
sampling devices 260a-d; and (9) location data of the air sampling
devices 260a-d.
[0046] Data obtained during the incubation period can include any
of the following: (1) identification data of the subjects 265a-265d
obtained by a barcode scanner; (2) location data of the subjects
265a-265d obtained by or generated by the barcode scanner; (3) the
date and time such location data was obtained, i.e., when the scan
was performed; (4) identification data of the person operating the
barcode scanner; (5) and remarks entered by a user. It is to be
understood that the date and time data for the scan may be
automatically generated by an internal electronic clock within the
touch panel 270 or the control center 210. Alternatively, such date
and time data may be manually entered by the user. The data may
also include the same data obtained during the air sampling period
above.
[0047] The control center 210 is the gateway of data and commands
received from the various components of the system 200, which may
log the data and commands in the database 290 for later retrieval
and/or which may provide real-time monitoring and display by the
control center 210. In an additional exemplary embodiment, the
touch panel 270 may access the historical data, such as past
identification data, location data, dates, times, etc., logged by
the control center 210 in the database 290. Using the touch panel
270, an operator may request information about a selected subject
265a-265d or the respective air sampling devices 260. The touch
panel 270 receives such selection and forwards it to the control
center 210. The control center 210 responds with the desired
current and/or historical data. For example, using the touch panel
270, the operator can select one of the subjects 265a-265d or air
sampling devices 260a-260d. The control center 210 responds with
identification data, historical location data, historical times and
dates of scans, etc. for the selected subject 265a-265d or air
sampling device 260a-260d. The touch panel 270 displays such
historical data.
[0048] To facilitate the real-time monitoring of the system 200 and
the logging of data regarding the system 200, the control center
210 includes any suitable computing processor or processing
platform that is capable of performing the functions and operations
of the exemplary embodiments of the control center 210 described
herein, e.g., real-time monitoring of data and commands in the
system 200, tracking and logging of data and commands of the system
200 in the database 290, and recalling of historical data stored in
the database 290. The control center 210 can include a
computer-readable medium comprising software code stored thereon
that, when executed by the control center 210, causes the control
center 210 to perform any of the functionality of the control
center 210 described herein. Thus, all or parts of the
functionality of the control center 210 that provide for remotely
monitoring the system 200, storing data and commands in the
database 290, and retrieving stored (historical) data from the
database 290 may be stored as computer-readable software
instructions in a computer-readable media and retrieved from the
computer-readable media and executed to perform the functions of
the control center 210 described herein.
[0049] The computing platform for the control center 210 is
desirably a PLC-based computer or server, either in a stand-alone
system or as part of a network. It is to be understood that the
control center 210 can be connected to any number of systems 200 at
any number of locations, thereby providing a mechanism for
monitoring and controlling multiple clean rooms 102 from a single,
central location. And, the same functionality may be provided via a
secure web site from which a user can remotely monitor and control
any number of systems 200 over the Internet from virtually any
location, adding yet another degree flexibility and accessibility
to the present invention. Thus, for instance, control center 210
can alert users in a first clean room of an alarm condition at an
air sampling device 260 located in a second clean room that is
separate and remote from the first clean room; and the user in the
second clean room monitor air sampling devices 260 in the first
clean room and clear alarm conditions in the first clean room. In a
further embodiment, touch panels 270 in the first clean room can
communicate with touch panels 270 in the second clean room, as
desired.
[0050] Turning to FIG. 3, the human computer interface 300
displayed on touch panels 270 is shown in greater detail. The
interface illustrated in FIG. 3 includes interface elements for
measuring, monitoring, and controlling the flow rate, as well as
detecting airflow errors during a sampling cycle at each of the air
sampling devices 260a-260d.
[0051] For example, the interface 300 may include a display that
can be read from multiple angles and distances and various buttons
or other user interface elements that allow the user to monitor or
adjust the various features of the air sampling devices 260a-260d.
Accordingly, providing a consistent interface 300 for each of a
number n of corresponding air sampling devices 260a-260d, each
touch panel 300 may be provided at a location where the air
sampling devices 260a-260d located throughout a clean room 102 can
be measured, monitored, and controlled.
[0052] Referring to FIG. 3, the interface 300 includes various
touch-sensitive screen portions for providing various functions and
information to users, which may hereinafter also be referred to as
"buttons." For example, button 302 may indicate an alarm condition
such as whether the current flow rate is outside of an acceptable
flow rate error threshold value (e.g., 1 CFM). By pressing the
button 302, the user may adjust this value for one or more of the
air sampling devices 260. The button 304 may also display the
current date and time. Similarly, by pressing the button 304, the
user may adjust the format and/or values of the date and time
displayed. The buttons 306 and 308 allow the user to load and to
save, respectively, configuration or other data in order to be
exported and analyzed by another system.
[0053] Columns 310, 312, 314, and 316 are each associated with a
different air sampling device 260a-260d or monitored zone. As
shown, columns 310-316 are associated with Lyophilizer Outfeeds
1-4, respectively. An image/icon 318 may be associated with each of
the columns 310-316 for indicating a flow rate for each air
sampling device 260a-260d. The icon 318 may also be animated to
further enhance the readability of the flow rate indication for
users. In the embodiment shown, each icon 318 includes five
downward facing arrows, where the length of each arrow provides a
visual indication of the flow rate. Longer arrows may indicate
higher flow rates, while shorter arrows may indicate lower flow
rates. Additionally, the direction of the arrows indicates the
directionality of the airflow, where downward animated arrows may
indicate an out-feed of air and upward animated arrows may indicate
an in-feed of air. If a zone 310-316 or an air sampling device 260
is off, then the corresponding icon 318 may also be off/not shown
for the affected zone 310-316.
[0054] Buttons and informational icons associated with the flow
rates for each of the zones 310-316 are shown in row 320. For
example, flow rate indicator 322 shows the current flow rate, such
as 1.0 CFM. The flow rate for one or more air sampling devices
260a-260d can be changed by pressing the up/down arrows 324 and
326, respectively, to increase or decrease the value that is
displayed, which is then transmitted to the control center 210 so
that the desired flow rate being displayed is implemented.
[0055] Row 330 shows information and controls associated with the
initiation and status of an air sampling test cycle as well as any
alarms. For example, time indicator 332 displays the amount of time
associated with a currently active or most recently completed air
sampling test cycle. As shown by time indicator 332, an air
sampling test cycle has forty three minutes and thirty five seconds
left for zone 310. Indicator 334 indicates whether an air sampling
test cycle is currently in progress (e.g., light on indicates a
test in progress, light off indicates no test in progress).
Similarly, indicator 336 indicates whether an air sampling test
cycle is complete (e.g., light on indicates a test is complete,
light off indicates a test is not yet complete).
[0056] The start/reset button 338 is utilized to initiate or
re-initiate a sampling cycle for an air sampling device 260a-260d,
where the sampling cycle continues until the user decides to abort
the sampling cycle by pressing the abort button 340. In one
embodiment, a typical sampling cycle may last between 10 minutes
and 3 hours.
[0057] In the event that an alarm or other error condition is
detected, the control center 210 may generate an alert/alarm, such
as when the flow measured for an air sampling device 216a, 216b,
216c, or 216d is outside of a desired flow rate. Each touch panel
270 may include a visual alert indicator for each air sampling
device 260a-260d, as indicated by columns 310-316, where the visual
alert indicators indicate if the air flow for a specific air
sampling device 260a-260d is outside of the desired flow rate.
[0058] As mentioned above, the control center 210 may be configured
to activate an alarm when a predetermined alarm condition has been
satisfied. The interface 300 also includes an alarm reset button
342. The alarm reset button 342 allows a user to manually reset
(i.e., turn off) all of the visual alert indicators after
identifying the air sampling devices 260a-260d at which errors
occurred during a sampling cycle.
[0059] In one embodiment, the predetermined alarm condition may
include when the actual rate of air flow at the one or more air
sampling devices 260a-260d deviates a predetermined amount from a
desired rate of air flow. In such an event, the control center 210
may be configured to activate a visual alarm, such as a strobe
and/or colored lights. Thus, for instance, the user interface 300
for a first touch panel 270a proximal to a first air sampling
device 260a, can receive the status of the air sampling devices
260a-d from the central control center 210; and display that status
in columns 310, 312, 314, 316, respectively. That first user
interface 300 can also be used to control the air sampling devices
260a-d (e.g., turn ON/OFF, clear an alarm, etc.) by communicating a
command signal to the central control center 210. And, that first
user interface 300 can send a command signal to the other touch
panels 270a-d, directly or preferably via the control center 210,
such as to clear an alarm.
[0060] In addition to the visual alarm, the control center 210 may
be configured to activate an audio alarm. For example, the audio
alarm may include one of a siren and a pre-recorded audio file.
Activating the alarm can also include activating an escalation
protocol whereby a predefined sequence of steps are taken in
response to the failure of a user to acknowledge the alarm within
one or more predefined time periods. For example, at a first step
in the escalation protocol, activating the alarm includes providing
a visual map of the location of the alarm condition at one or all
of the touch panels 270. If the alarm is not acknowledged, such as
by pressing the alarm reset button 342 on the touch panel 270, an
email may be sent to one or more designated users. A third step in
the escalation protocol may include sending a simple message
service (SMS) text message to a user's mobile device. If the alarm
is still not acknowledged, a phone call may be automatically placed
to one or more users and playing a designated pre-recorded sound
file. Finally, a message may be sent one or more users located
remotely from the facility associated with the alarm in order to
address the detected alarm condition.
[0061] It is appreciated that, in some embodiments, the audible
alarm may continue until the error conditions are removed or
acknowledged yet the visual alert indicator may remain on even
after the error conditions are removed or acknowledged. This allows
a user to determine, sometime after the alarm signal was generated
and/or after the sampling cycle, which of the multiple air sampling
devices 260a-260d experienced an error condition during the
sampling cycle. Accordingly, the user to can remain focused on his
or her work in the clean room 102 rather than having to immediately
check which air sampling device 260a-260d is experiencing errors
every time an audible error alert sounds. If all of the error
conditions have been removed and all of the flow rates have
returned to the desired level, all of the visual alert indicators
will turn off. For any air sampling devices 260a-260d for which an
error condition still exists, the visual alert indicator may remain
on.
[0062] It is appreciated that one advantage of the present
invention includes simplifying the configuration of the air
sampling devices and related components necessary for monitoring
and controlling air sampling in a controlled environment by
avoiding the need for certain components, such as conventional flow
switches. The present invention also provides a high degree of
flexibility to rearrange a display to show any number of individual
parameters associated with air sampling and monitoring including,
but not limited to, the location name, sample time, or duration of
air quality tests. Because conventional devices are not PLC-based
and therefore are not programmable, as new features are created,
physical changes to the hardware are required and do not allow for
the collection of time sample data. The present invention overcomes
these shortcomings by providing a flexible, programmable air
sampling and monitoring system that includes a programmable logic
controller-based control center and a plurality of associated touch
panel displays sharing a unified interface.
[0063] These and other advantages of the present invention will be
apparent to those skilled in the art from the foregoing
specification. Accordingly, it is to be recognized by those skilled
in the art that changes or modifications may be made to the
above-described embodiments without departing from the broad
inventive concepts of the invention. It is to be understood that
this invention is not limited to the particular embodiments
described herein, but is intended to include all changes and
modifications that are within the scope and spirit of the
invention.
* * * * *