A Digital Twin for Analysis of Radiation Heating in Thermoforming Processes

Modeling heating phenomena for industrial applications is crucial for both the optimization and performance control of these systems. In this work, we focus on creating a modular digital twin for modeling thermoforming systems based on a lumped parameter model. This paper discusses and demonstrates the validity of a complete model-based digital twin and data integration system to analyze a direct heating system with ceramic heating elements. A cascade model describing the system’s main features is presented: the heaters, the view factor explaining the effect of the heaters on the sheet, and finally, a heating model of a flat polymer sheet. Validation of the model is then done using finite element software. The proposed mathematical model has low complexity and is useful in the development of improved control strategies, optimization of geometric parameters, analysis of disturbance reduction techniques, heater characterization, and sensory system definition.