The Dukane MPC (Multi-Point Control) system solves a fundamental problem in multi-point ultrasonic welding: how to drive and independently monitor multiple ultrasonic probes without stacking separate generators for each weld point. A single iQ series generator — rated at 600 W or 1200 W — sequences across 2 to 16 probes, each with its own independently configurable weld parameters. This cuts electrical cabinet footprint, cabling complexity, and generator cost compared to multi-generator architectures, while the patented sequencing logic ensures only one probe is active at any instant.

How does per-probe process monitoring work?

The MPC samples and processes data for each weld point every 0.5 milliseconds across a multi-core architecture. Each probe can be assigned its own weld mode — time, energy, peak power, or optional distance-based collapse control — with independent upper and lower limit alarms. When a weld falls outside its specified window, the MPC flags that specific probe position as suspect or bad. An illuminated part map on the operator interface can be configured to show exactly which weld point failed, allowing operators to isolate defective parts without stopping the entire line to troubleshoot. Ring-down monitoring prevents relay switching while ultrasonic voltage is present, protecting probes from electrical damage.

What fieldbus protocols does the MPC support?

The MPC is designed for automated assembly cells and in-line production, with native support for EtherNet/IP, Profibus, Profinet, EtherCAT, PowerLink, CC-Link, and Modbus TCP. This breadth of protocol coverage means the MPC can integrate into existing PLC architectures without protocol converters or gateway modules. Digital I/O includes binary-coded probe selection inputs with logic interlocks that prevent simultaneous selection of two probe relays. A fault monitor detects shorted relay coil drivers and halts operation before hardware damage occurs.