Hurco Retrofit

Modern manufacturing demands precision, speed, and uptime—but aging press brakes often struggle to keep pace. A Press Break retrofit swaps out obsolete control electronics for a PC-based system, transforming your existing brake into a high-performance asset. Instead of investing in a brand-new machine, a retrofit leverages your current hydraulics and frame, delivering faster setups, tighter tolerances, and years of additional service life.  What Is a Press Break Retrofit? A Press Break retrofit involves removing the original control panel, CPUs, and I/O modules from your press brake and installing a standardized PC800 control enclosure. This turnkey upgrade seamlessly integrates with your back-gauge, crowning system, safety interlocks, and foot pedal, while layering in modern software features—like graphical programming, automated bend sequences, and real-time diagnostics. Core Elements of a Press Break Retrofit When you choose a press break retrofit from PC Controls, you gain: PC800 Touchscreen Interface A rugged 19" industrial display running intuitive software, replacing dozens of archaic buttons and switches. Graphical Bend Wizard Software Automatically generates bend sequences from imported CAD or DXF files, letting operators preview each step and adjust on-screen before touching the brake. Advanced Safety Integration Electronic light-curtain and gate monitoring tie directly into the control’s I/O modules, ensuring full compliance with current OSHA and CE standards. Back-Gauge & Crowning Interface Multi-axis positioning delivers programmable crowning, taper compensation, and programmable offsets for complex bending operations. Remote Diagnostics & Support Built-in VPN and remote-access tools enable PC Controls engineers to troubleshoot faults, deploy updates, and optimize parameters without an on-site visit. Hydraulic Leveling Valve Upgrade Peak productivity demands consistent ram parallelism across the bed. As part of a press break retrofit, an electronic hydraulic leveling valve replaces your manual or analog system: Dual Linear Scale Feedback measures ram alignment in real time. Electronic Valve Control adjusts crown settings automatically, ensuring uniform bending pressure across long parts. Programmable Crown Profiles let you switch between tapers, radii, or multi-step bends at the touch of a button—no manual shim changes required. The result is first-pass accuracy on every job, even when switching between thin sheets and heavy plate. Productivity & Accuracy Gains Shops that invest in a press break retrofit typically see immediate improvements: 30–40% Faster Setups by loading CAD profiles directly into Bend Wizard, eliminating manual calculation and trial bends. 20–25% Scrap Reduction thanks to on-screen simulation and automated crowning—first-part success becomes the norm. Minimized Downtime as solid-state drives, modern processors, and standardized I/O modules replace flaky legacy electronics. Beyond speed and quality, the modern control platform generates maintenance logs, alarm histories, and usage analytics—helping you plan preventive service rather than react to failures. When to Schedule Your Retrofit To maximize ROI and minimize disruption, plan your press break retrofit: During Planned Maintenance Windows : Coordinate with annual shutdowns or slow seasons. Before Major Production Runs : Ensure peak reliability when tackling high-volume orders. When OEM Support Ends : Retrofits safeguard against obsolete control boards that are no longer stocked. To Meet New Safety Standards : Leverage modern control interlocks and monitoring to comply with updated regulations. Early planning prevents the unplanned downtime that can cripple delivery schedules and customer confidence. Case Study: Boosting Throughput at a Regional Fab Shop A Midwestern sheet-metal shop retrofitted their 100-ton press brake with PC800 controls, Bend Wizard, and an electronic leveling valve. In six months they reported: 35% Reduction in Setup Time – standard jobs went from 25 minutes to under 16 minutes. 18% Less Scrap – perfect first-part accuracy on complex angles. Zero Control-Related Failures – legacy board failures dropped to zero after retrofit. The total retrofit paid for itself in just five months through labor savings and reduced material waste. Ready to Unlock Peak Productivity? Don’t let outdated controls slow your shop down. Contact PC Controls today for a customized Press Break retrofit proposal and transform your existing brake into a modern, high-efficiency powerhouse.

Upgrading your press brake doesn’t always mean buying new equipment. A Cincinnati retrofit replaces aging control hardware on legacy press brakes—like the Autoshape or CB series—with PC Controls’ modern PC800 control platform and Bend Wizard software. This turnkey solution revitalizes your machine’s accuracy, reduces downtime, and delivers a rapid return on investment at a fraction of the cost of an OEM replacement.  What Is a Cincinnati Retrofit? A Cincinnati retrofit involves stripping out obsolete Cincinnati control electronics—legacy CPUs, custom panels, and unsupported I/O boards—and installing a standardized, PC-based control enclosure. The retrofit harnesses your existing hydraulic system and back-gauge mechanics, layering on intuitive graphical programming, real-time diagnostics, and remote support capabilities. Key Components of the PC800 Cincinnati Retrofit Kit 19″ Touchscreen Control Panel : A rugged, industrial-grade display runs PC800 software, providing drag-and-drop part setup. Bend Wizard Software : Automatically generates bend sequences from imported DXF or CAD profiles, eliminating manual calculation errors. Back-Gauge Interface Module : Plugs into your existing stepper or servo motors, enabling multi-axis positioning and programmable crowning. Foot Pedal & Safety Integration : Retains your shop’s footswitch and light-curtain safety circuits, with electronic interlocks managed by the PC800 I/O modules. Remote Diagnostics & Updates : Built-in VPN and TeamViewer support let PC Controls engineers troubleshoot issues and install firmware updates without an on-site visit. Cincinnati Retrofit vs. OEM Replacement Cost Efficiency : A Cincinnati retrofit typically runs 30–40% of the price of a comparable new machine, preserving your capital budget. Lead Time : Retrofit projects can be completed in days rather than the months often required for a new press brake delivery. Customization : Unlike off-the-shelf machines, each retrofit is tailored to your workflow—whether you need custom gauge lengths, specialized crowning, or unique safety features. Sustainability : Retrofitting reduces waste by extending the useful life of your existing equipment, aligning with green manufacturing goals. Case Study: Modernizing a Cincinnati Autoshape A Midwest fabrication shop retrofitted their 150-ton Cincinnati Autoshape press brake with PC800 controls and Bend Wizard. Within three months they reported: 25% Faster Setup Times : Graphical programming cut setup from 30 minutes to 22 minutes on average. 20% Scrap Reduction : First-pass success increased as Bend Wizard guided operators through each bend sequence. Zero Control-Related Downtime : The shop eliminated failures caused by discontinued Cincinnati CPU boards. The total retrofit paid for itself in under five months through labor savings and reduced material waste. When to Schedule Your Cincinnati Retrofit During Planned Maintenance : Coordinate the retrofit with annual shutdowns to avoid unplanned production losses. Before Large Runs : Ensure your press brake is fully reliable ahead of high-volume or high-precision orders. When Legacy Support Ends : OEM control support for many Cincinnati series ceased years ago—proactively retrofit before parts become unobtainable. To Improve Safety : Upgraded controls support modern light-curtains and electronic guard monitoring to meet current regulations. Ready to Upgrade? Don’t let obsolete controls limit your shop’s potential. Contact PC Controls today for a custom Cincinnati retrofit quote and transform your press brake into a modern, high-performance workhorse.

Upgrading your CNC control system doesn’t always mean investing in a brand-new machine. A CNC control retrofit replaces aging, unsupported electronics with a modern, PC-based control platform—extending equipment life, boosting productivity, and delivering a rapid return on investment. What Is a CNC Control Retrofit? A CNC control retrofit involves removing obsolete control hardware—keyboards, joysticks, legacy processors—and installing a PC-based control system like the PC800. This turnkey upgrade provides graphical programming interfaces (Bend Wizard, Shear Wizard, Punch Wizard), real-time diagnostics, and seamless integration with existing hydraulics and back-gauges. Signs Your Machine Needs a Retrofit Consider a retrofit when you encounter any of the following: Frequent Downtime: Old electronics fail more often, interrupting production. Obsolete Parts: Legacy control boards are no longer supported or stocked. Limited Programmability: You can’t run advanced software features—DXF import, 2D/3D part simulation, or auto-program creation. These pain points often surface in shops running 15–20-year-old CNC systems—prime candidates for a cost-effective retrofit. The Retrofit Process Consultation & Assessment Our team evaluates your machine model (press brake, shear, punch) and determines compatibility with the PC800 control. Custom Control Design We tailor the PC800 control panel to your workflow, integrating Bend Wizard for press brakes, Shear Wizard for shears, or Punch Wizard for single punches. On-Site Installation & Commissioning Certified technicians remove old electronics, mount the PC800 enclosure, connect linear scales, back-gauges, and safety interlocks, then calibrate the system. Installation by experts ensures minimal downtime. Operator Training & Support We provide hands-on training so your team masters the new graphical UI and maintenance tools. Post-retrofit support includes remote diagnostics and comprehensive product literature. Key Benefits of a CNC Control Retrofit Extended Machine Lifespan: Upgrade controls for a fraction of the cost of a new machine—gain another 10+ years of service. Improved Uptime & Reliability: PC-based hardware with solid-state drives and modern processors reduces failures and simplifies troubleshooting. Intuitive Graphical Interface: Visual part simulation and DXF import speed programming and lower the learning curve for new operators. Real-Time Monitoring & Diagnostics: Built-in alarms, status logs, and maintenance prompts let you fix issues before they halt production. Rapid ROI: Many fabricators recoup retrofit costs in under six months through reduced maintenance and faster setups. When to Schedule Your Retrofit Before Major Production Runs: Avoid unplanned downtime by retrofitting during planned maintenance windows. When Legacy Support Ends: Control manufacturers often discontinue support after 10–15 years—plan ahead to prevent disruptions. Prior to Process Expansion: New product lines requiring tighter tolerances or complex geometries demand modern control features. To Improve Safety & Compliance: Modern controls support safety interlocks, light-curtains, and guard monitoring—critical for meeting updated regulations.  Case Study: Fast Payback in a Mid-Size Shop A regional fab shop retrofitted two 200-ton press brakes with PC800 controls and Bend Wizard software. Within three months, they: Reduced setup time by 25% Cut scrap rates by 15% Eliminated obsolete control-board failures The total retrofit investment was recouped in under four months—transforming aging equipment into reliable, high-precision workhorses. Ready to Modernize? Don’t let outdated CNC controls hold your shop back. Contact PC Controls today for a custom CNC control retrofit quote and breathe new life into your metal-forming equipment.

In today’s fast-paced metal fabrication industry, staying competitive means modernizing equipment without incurring the steep costs of full machine replacements. CNC Retrofits are emerging as a cost-effective solution to revitalize aging machinery while ensuring that production remains efficient, precise, and adaptable to modern requirements.

Understanding CNC Retrofits

CNC retrofits involve upgrading older machines with PC-based control systems that provide state-of-the-art interfaces and real-time monitoring capabilities. This process allows fabricators to:

• Integrate Modern Software: Replace outdated control panels with intuitive software solutions like Bend Wizard, Shear Wizard, and Punch Wizard.
• Improve Operational Precision: Benefit from enhanced control features that improve accuracy in metal fabrication processes.
• Extend Machine Lifespan: Maximize the value of existing machinery by updating only the control system rather than purchasing entirely new equipment.

Why Upgrading Matters

Many metal fabricators face challenges with obsolete CNC systems, including limited functionality and increased downtime. Modernizing these systems offers several benefits:

• Enhanced Production Efficiency: New control systems streamline processes and reduce cycle times.
• Reduced Maintenance Costs: Modern interfaces simplify troubleshooting and repair, helping to lower long-term maintenance expenses.
• Competitive Advantage: Upgraded machines are better equipped to handle the precision and complexity demanded by modern fabrication techniques.

Product Spotlight: Press Kit and Punch Kit

At PC Controls, the focus is on providing tailored retrofit solutions:

• Press Kit: Designed specifically for press brakes and related machinery, the Press Kit integrates modern PC-based controls with existing hardware. This upgrade enhances the machine’s performance, ensuring smoother operation and improved precision.
• Punch Kit: Ideal for retrofitting single punches and other forming equipment, the Punch Kit offers robust control solutions that bring advanced diagnostics and real-time feedback to traditional machinery.

These products are part of a broader suite of offerings that not only improve machine functionality but also extend the life of the equipment, ensuring that fabricators can continue to produce high-quality work without interruption.

Real-World Applications

Many companies are turning to CNC retrofits as a way to solve common industry challenges:

• Reducing Downtime: Upgraded controls allow for faster diagnostics and quicker repairs, minimizing production interruptions.
• Improving Product Quality: Enhanced precision means fewer errors and less material waste, resulting in better end products.
• Cost Savings: By updating only the control systems, companies avoid the significant capital expense associated with purchasing brand-new machinery.

Tips for a Successful Retrofit

Implementing a CNC retrofit project requires careful planning:

• Evaluate Your Needs: Consider which parts of your machine require the most attention. Focus on areas that directly impact productivity and quality.
• Plan for Integration: Ensure that new controls can be seamlessly integrated with your existing equipment. This might involve minor modifications or additional support services.
• Train Your Team: Modern systems come with advanced features. Investing in proper training will maximize the benefits of the retrofit and ensure your staff can leverage all available functionalities.

Embracing CNC Retrofits is a strategic move that can significantly boost operational efficiency, reduce downtime, and enhance product quality—all without the need for a complete machine overhaul. With innovative solutions like the Press Kit and Punch Kit, metal fabricators have the tools to transform aging equipment into modern, reliable production workhorses. By choosing a retrofit approach, businesses can secure a competitive edge while safeguarding their investment in legacy machinery.