Magnetic flux control plays a key role in optimal coil design. We offer custom induction coil design to maximize production efficiencies to produce better parts for less cost.
Fluxtrol Induction Heating Coil

Scanning simulation using ELTA software Scanning heating of water-cooled plate demonstrating effect of Fluxtrol concentrator

As a starting point in assisting you in induction coil design, our engineering department makes a detailed analysis of the product heat treatment requirement and production environment (i.e.,workpiece material/geometry, heat treatment specification, production rate, sequence of operations, material handling equipment and available induction heating system parameters, etc.) and then considers other coil development stages including:
  • Heating style (limited control due to existing machines or bill of process)
  • Inductor design (coil style selection, copper cross-section, controller manufacturing & application, etc.)
  • Inductor engineering & fabrication
  • Inductor matching
  • Inductor set-up and tests
  • Final modification of inductor & process (if required)

Establishing optimal coil design and manufacturing criteria essentially is defined by a scientific procedure incorporating computer simulation for predictable results in advance of any tooling fabrication.

Induction Coil Design Optimization

Original Inductor

Original Inductor

Optimized Fluxtrol Inductor

Optimized Inductor

Original inductor for plastic coating to auto stub shaft had improper temperature distribution and was subjected to mechanical damage by parts.

New potted inductor with local Fluxtrol controller and protective cap provides excellent heat pattern control, mechanical properties and improved efficiency.

Original Coil Design

Original Coil Design

Optimized Fluxtrol Induction Heating Coil Design

Optimized Coil Design

“Complex” Inductor

(Optimized design shown)
Shifter Fork Hardening Inductor

Shifter Fork Hardening Inductor

Inductor and Component w/Handling Fixture

Inductor and Component w/Handling Fixture

Clutch Plate Hardening Inductor

Clutch Plate Hardening Inductor

Clutch Plate Hardening Inductor

Clutch Plate Hardening Inductor

Sprocket Tip Hardening Inductor

Sprocket Tip Hardening Inductor

Sprocket Tip Hardening Inductor

Sprocket Tip Hardening Inductor