Technology, simulation and control for induction heating processes
Aselt uses mathematical models and FEM simulation to optimise induction heating processes, improving quality, efficiency and traceability.
Technology is the heart of the Aselt method
Every system, treatment or component starts from a scientific approach that combines electro-thermal analysis, field experience and digital parameter control. Through proprietary calculation tools and monitoring systems, Aselt delivers repeatable results, lower energy costs and long-term reliability.
Our technologies
Predict to control
FEM (Finite Element Method) simulation is a fundamental tool in Aselt’s design process.
Through three-dimensional analysis of the magnetic field and heat distribution, it is possible to predict the behaviour of the workpiece before the system or coil is even built.
Main benefits of FEM simulation:
- Full visualisation of the magnetic field.
- Control of heating depth and surface temperature.
- Optimisation of power and frequency parameters.
- Reduced losses and uniform treatment.
This phase makes it possible to move from calculation to production with real data,
eliminating uncertainty and repeated testing.
This phase makes it possible to move from calculation to production with real data, eliminating uncertainty and repeated testing.
Coupled electro-thermal analysis
During the design phase, Aselt uses coupled electro-thermal models to simultaneously study the magnetic field distribution and the thermal response of the treated material.
This approach determines:
- The amount of heat generated at every point.
- The heating rate.
- Cycle stability.
- Thermal deformation of the component.
Application example: when hardening a crankshaft, simulation ensures a uniform temperature across the hardened area, avoiding overheating and internal stresses.
Magnetic field and material optimisation
The efficiency of an induction heating system strongly depends on the coil geometry and magnetic flux distribution.
Thanks to FEM simulation, Aselt can optimise:
- The shape of the windings.
- The positioning of magnetic flux concentrators.
- The gap between coil and workpiece.
- Power balancing across the active zones.
To maximise performance, high-efficiency materials are used, such as:
- Cu+Ag 0.1% copper, to reduce electrical losses.
- Fluxtrol®, to concentrate the magnetic field.
- Silicon nitride (Si₃N₄), as mechanical and thermal insulation.
Integration with the IPC system
FEM technology is completed by the IPC process control, a system developed entirely by Aselt. While simulation predicts the ideal behaviour of the cycle, IPC monitors the actual parameters in real time: current, voltage and coil position.
Benefits of FEM + IPC integration:
- Design validation before production.
- Real-time control during processing.
- Fewer human errors.
- Complete digital report for every part.
Energy efficiency and sustainability
Aselt designs its systems with energy efficiency and environmental sustainability in mind. By optimising heating parameters and integrating heat recovery, energy consumption can be reduced by up to 30% compared with traditional processes.
Measures adopted:
- Minimised magnetic losses.
- Heat recovery through exchangers.
- Long-lasting, recyclable materials.
- Fewer physical tests and less production waste.
Research and development
Innovation is an integral part of the Aselt method.
We work with universities and research laboratories to develop new predictive FEM models, advanced magnetic materials and simulation software.
Every year we introduce improvements in control systems, coil design and generator architectures.
This constant commitment to research keeps our technological standards aligned with the most advanced markets.