Two mathematical models are derived to describe the thermal dynamics of a plastics production machine. The Smart Sensor design is based on the finite volume model. The accuracy of the derived finite volume model is validated by a high-order finite element model. Those models are validated by measurements. A Smart Sensor for the heat flow between the extruder cylinder and screw conveyor is designed. Such a configuration has the advantage to decouple the thermal control problem from the specific granulate.
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