Modelling and Analysis of Radiation Heating in Thermoforming Processes

An effective mathematical model of a complex phenomenon like radiation heating in industrial systems is critical for optimal design and subsequent performance control. In this paper, we propose the creation of a complete digital twin based on a mathematical model integrated with field-measured data. The model’s validity was then verified with experiments performed on the bench. The presented model is cascaded and describes the three main features of the system: the heaters, the view factor explaining the effect of each heater on the sheet, and finally, a model of heating a flat polymer sheet. Due to the low complexity of the proposed mathematical model, it allows to develop advanced control strategies and to perform analysis and optimization of the principal geometrical parameters of the system. Furthermore, it is able to support the identification of the best configuration and placement of the sensory system.