Modular Drive System

Powerful, Precise, and Versatile Adaptable Welding Equipment and Cutting Mechanization Solutions!

The Modular Drive System is the only product in the industry that allows the user to configure one machine for multiple applications. The Master Drive Unit accepts several interchangeable control modules for programmable shape cutting, straight line cutting/welding, and stitch welding. Other adaptable applications include programmable stitch welding, arc gouging, linear weaving, and pendulum weaving.

Custom Cutting and Welding System Benefits:

  • High torque, low inertia motor
  • Dedicated fail-safe brake
  • Motor overload protection
  • Closed loop speed control
  • Closed loop position control
  • Made in USA

Master Drive Unit

At the heart of the Modular Drive System is the Master Drive Unit. This piece houses the industrial cutting machine’s motor, speed control board, power supply, and clutch that allows rapid manual positioning of the carriage anywhere along the track. The unit runs from 2-120 in/min (51-3048 mm/min) with a vertical load capacity of 60 lbs (27 kg) and a horizontal load capacity of 100 lbs (45 kg).

The Master Drive Unit has a high torque, low inertia motor for precise stops and starts. Moreover, it features a dedicated fail-safe brake with three times the stopping and holding power of the motor. The unit is equipped with motor overload protection which turns the motor off and engages the brake whenever an excessive load is placed on the machine. In addition, the Master Drive features closed-loop speed control for adjustable, repeatable control of critical welding or cutting parameters and closed-loop position control to prevent creep.

Modular Drive System Kits are all in one package based on application. All kits include: a master drive, control module, racking, torch holder, rail, and magnets. Only the welding kits include a torch with the kit. Please see our Product Catalog (pages 3-5) for kit options.


Remote Control Cable

It is installed between the Master Drive Unit and the Control Module. This allows the operator to handle the adaptable welding equipment and perform work in confined areas where it would be difficult to reach the controls.

MDS-1060-10 – 10 ft (3 m) Length
MDS-1060-25 – 25 ft (7.6 m) Length

Weld Contact Cable

It provides the required connection to control a wire feeder contractor circuit from the MDS Control Module.

MDS-1085 – 10′ (3.05 m) Length
MDS-1085-25 – 25′ (7.62 m) Length
MDS-1085-50 – 50′ (15.24 m) Length

Automatic Height Control System

It mounts on the welding equipment’s Master Drive Unit and includes Remote Control Cable. It provides automatic control of torch height when using the welding system with a CV welding machine process. Includes controls for: current set point, auto/manual and torch raise/lower.

CAS-2050 (For WPD-1100 Linear Weaver)
CAS-2060 (For WPD-2100 Pendulum Weaver)

Extended Mounting Plate

It mounts to the front of the carriage for use with dual cutting or welding groups, heavy-duty racking, etc.


Quick Action Manifold

It Allows quick On/Off of preset torch and eliminates hose strain.

MDS-3025 – 2-Hose
MDS-9898 – 3-Hose

Hose Assemblies
CIR-1010-3 – 2-Hose
MUG-1119-32 – 3-Hose

Universal Limit Kit

It installs between the Master Drive Unit and any of the control modules on the industrial cutting machine. This limit kit adds the ability to cycle between limits, stop at limit, or rapid return. All existing functions of the control modules are maintained.

MDS-1055 – For Rigid Rail Applications
FMD-1045 – For Hi-Flex Rail Applications

Handle with Cable Anchor

It keeps welding cables and contact wires away from the work surface. It serves to eliminate drag from this welding equipment.


Racking Groups:

Machined Rack Cutting Group

Machined Rack Welding Group

Control Modules:

A Control Module plugs into the top of the Master Drive Unit and operates various machine functions. There are several control modules available for you to customize your welding system. These include programmable shape cutting or welding, straight-line cutting, and/or welding. Moreover, this customizable industrial cutting machine’s control module can be programmed for straight-line gouging, programmable stitch welding as well as weave welding capability.

Programmable Shape Module (MDS-1165)

The MDS Programmable Shape Module provides a 2-axis, encoder-controlled, all-position, custom shape motion. Shapes and patterns are built by segments to control motion and function. The 2-axis motion is provided by the MDS Master drive and the Linear Weaver w/ 40″ (101.6 cm) Crossarm.

Straight Module (MDS-1002)

The MDS-1002 Straight Control Module provides direction and speed control for continuous cutting or welding applications with this adaptable welding equipment.

Stitch Module (MDS-1003)

The MDS-1003 Stitch Module provides direction and speed control for continuous travel or Stitch Mode with adjustments for travel time, rapid time, and puddle build/crater fill times.

Programmable Stitch Module (MDS-1004)

The MDS-1004 Programmable Module provides stitch controls for welding or cutting with the Modular Drive Cutting and Welding System. Program Stitch by distance, automatic stop and/or return to start at the end of the cycle, independent timers for puddle-buildup. All stitching parameters are set and displayed on a graphic screen. This allows each setting to be programmed exactly the same every time you use the customizable industrial cutting machine.

Arc Gouger Straight Module (AGS-1002)

The AGS-1002 Arc Gouging Straight Control Module provides direction and speed control for the AGS gouging systems. This Control Module interfaces with the Arc Gouging system to automatically provide travel when the arc is established.


The Weaver Control Module operates the Pendulum or Linear Weaver, and the Master Drive Unit. The Control Module features include: a digital readout and control knob for longitudinal travel speed; a switch for Forward/Stop/Reverse tractor control; an amplitude knob to set weave width from 1/8″-2″ (3-50 mm); weave speed control up to 100 in/min (254 cm/min); controls for left and right dwell; a knob to control steering up to 2″ (50 mm), either side of center; weld contact; and a power On/Off switch.

One of four weld patterns can be chosen using the mode selector switch, as shown in the figure below. The MDS-1005-DIAL Weaver Control Module w/ locking dials provides all of the function controls of the MDS-1005 and provides lockable numerical display dials for all oscillator functions.

Linear Weaver (WPD-1100)

The Linear Weaver and the Weaver Control Module provide the Modular Drive Adaptable Welding Equipment with linear weave motion, producing welds from 1/8″ to 2″ (3-50 mm) wide. The Linear Weaver bolts onto the front of the Carriage, and the Weaver Control Module plugs into the top of the Master Drive Unit, as shown below. The Linear Weaver also has motor overload protection which turns off the motor when too much load is placed on the Linear Weaver.

Pendulum Weaver (WPD-2100)

The Pendulum Weaver and the Weaver Control Module provide a pendulum weaving motion to the Modular Drive Cutting and Welding System. The Pendulum Weaver is particularly useful for weaving filet welds in a corner joint. The Pendulum Weaver supports bolts onto the front of the carriage, and the Weaver Control Module plugs into the top of the Master Drive Unit, as shown below. The Pendulum Weaver has a heavy-duty planetary gearbox with powerful output for rotating the welding gun and attachments.


This adaptable Welding Equipment’s Linear/Pendulum Weaver and Weaver Control Module incorporate the following standard features:


  • High torque, low inertia motor for precise starts and stops.
  • High-speed Linear/Pendulum Weaver for weaving, with independent control of right and left dwell times.
  • High motor gearing, which prevents the cross-arm from moving when the unit is turned off.
  • Closed loop speed control for adjustable and repeatable control of critical welding parameters.
  • Closed loop position control to prevent drift from the weld center position.
  • Clutch, to enable rapid installation or replacement of the weaver cross arm.
  • A gun-mounting group with adjustable racking for accurate positioning of the gun.
  • Contactor ON/OFF switch.

Get In Touch


Whether you have questions about our operator-controlled machines or are interested in buying and need to contact a distributor, we can help. Contact us by filling out our form below or giving us a call. At Bug-O Systems, we are ready to help you access high-quality and efficient mechanized solutions.


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Canonsburg, PA 15317

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