How the IPC system works
The IPC system acquires and analyses signals from current, voltage and magnetic field sensors. The data is converted and compared in real time with the reference values recorded during calibration.
The operating process includes data sampling during processing, automatic comparison with the virtual master, detection of deviations from the set tolerances and recording of results with digital report generation.
The system can operate either independently or integrated with Aselt generators and control panels.
The virtual master concept
The virtual master is the heart of the IPC system. It is generated by recording the electro-thermal profile of a sample part validated by the metallurgical laboratory.
Every subsequent production cycle is compared with this digital model to identify, in real time, any deviation from the ideal behaviour.
The main advantages include fewer destructive post-process tests, objective and repeatable analysis, drastically reduced inspection times and complete traceability of the production process.
Monitored parameters
The IPC system simultaneously monitors a series of electrical and thermal parameters that are fundamental to the induction heating process.
These include input and output current and voltage, instantaneous and average power, power factor and oscillation frequency.
All parameters are saved in real time in the system database, with automatic data export in CSV, PDF or XML format.
Integration with industrial systems and software
The IPC system can be integrated directly into Aselt control panels or installed as an external module on third-party systems.
Using standard protocols such as Modbus, OPC-UA and Profinet, it communicates easily with SCADA, MES and ERP supervision systems.
Advanced features include remote connection via Ethernet or Wi-Fi, analysis dashboards with graphic trends and process curves, user management with differentiated access levels and multi-platform compatibility with Windows, Linux and embedded PLC environments.
Quality control and traceability
With the IPC system, every production cycle is recorded and linked to a unique identifier of the processed part.
This enables complete process traceability, particularly useful for internal audits and advanced statistical analysis.
Customer benefits include guaranteed quality on every part, fewer rejects and rework and an overall improvement in production and predictive efficiency.
Predictive diagnostics
The IPC system integrates advanced predictive diagnostics features, going beyond simple process control.
By analysing variations in current, voltage and temperature over time, the system can detect early signs of degradation in coils, transformers or generators.
This enables planned maintenance, a significant reduction in plant downtime and a longer service life for components.
Industrial applications
The Aselt IPC system is installed on hardening and tempering systems, high-frequency brazing, localised heating and automated production lines.
It is compatible with all major industrial automation systems and can also be adapted to existing machines, ensuring maximum integration flexibility.