ASELT srl

IPC process control

Quality guaranteed at every cycle. The IPC (Induction Process Control) system developed by Aselt monitors and certifies induction heating processes in real time, ensuring 100% traceability and quality.

PROCESS CONTROL

Quality, traceability and control
for every production cycle

In induction heating, quality depends on process consistency.
 Even a minimal variation in current, distance or temperature can compromise the outcome of the treatment.
 That is why Aselt developed the IPC system, an intelligent digital control that records, compares and validates every production cycle.

IPC is the natural evolution of induction technology: it combines electronic measurement, software analysis and industrial automation, turning heating into a traceable, documented and predictable process.

The IPC system

What the IPC system is

The Induction Process Control (IPC) is an electronic system developed by Aselt to monitor electro-thermal parameters during induction heat treatments.
 It continuously measures voltage, current, power and magnetic field, comparing the values with a reference model called the virtual master.

When the parameters of a production cycle drift outside the defined tolerances, the system:

  • generates an automatic alert,

  • flags the non-conforming part,

and stores the cycle for later analysis.

Virtual master

The virtual master concept

The virtual master is the digital profile that represents the ideal behaviour of the process.
 It is generated on a sample part validated in the laboratory and used as a reference for all subsequent cycles.

Every treatment is then compared against this profile, allowing the IPC to detect even minimal deviations in real time and automatically correct power or frequency.

The result:

  • Non-destructive quality control.

  • Guaranteed cycle repeatability.

  • Objective, certifiable analysis.

  • Monitored parameters

    The IPC system simultaneously monitors electrical, magnetic and thermal parameters, allowing a complete analysis of the process:

    • RMS current and voltage.

    • Instantaneous and average power.

    • Operating frequency.

    • Phase and power factor.

    • Surface and core temperature (via IR sensors or thermocouples).

    • Gap between coil and workpiece.

    • Cooling water flow.

    This data is displayed on an intuitive graphic interface and automatically archived for every cycle.

System integration

Integration with systems and machinery

The IPC system can be installed both on Aselt systems and on third-party machines.
 Thanks to industrial PLCs and standard protocols such as Modbus, Profinet and OPC-UA, it can communicate with generators, control panels, SCADA or company MES systems.

Possible configurations:

  • Direct integration into Aselt control panels.

  • External modular connection on existing systems.

Remote supervision via Ethernet or Wi-Fi connection.

Digital traceability

Quality control and digital traceability

With IPC, every production cycle is stored in the internal database with a unique identification code.
 The system generates an automatic report containing parameter charts, detected deviations and the validation result.

Benefits for the customer:

  • Complete digital traceability.

  • ISO 9001 compliant documentation.

  • Statistical cycle analysis.

  • Lower reject rates and inspection costs.

With IPC, the induction heating process becomes certifiable, repeatable and transparent.

Predictive analysis and diagnostics

IPC is also a predictive diagnostics tool.
 By collecting historical data, it identifies abnormal trends – such as current variations or efficiency drops – and reports them before a failure occurs.

This approach enables:

  • planned maintenance instead of reactive repairs,

  • less machine downtime,

  • longer service life for coils and transformers,

  • higher production availability.

Industrial applications

Industrial applications

The IPC system is installed on systems for:

  • hardening and tempering,

  • high-frequency brazing,

  • localised heating,

  • automated production and continuous lines.

Its flexibility makes it suitable both for new systems and for industrial retrofits, upgrading machines already in operation.