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Retrofit Scope

Re-engineer Beckhoff-based control and motion functions around a suitable Bochu platform with machine-specific EtherCAT and I/O planning.

PLC, NC and EtherCAT topology survey
Motion, servo, fieldbus and I/O migration
Height control, cutting process and functional validation

Beckhoff EtherCAT cabinet and servo wiring assessed for a CypCut retrofit — Beckhoff-to-CypCut retrofit: EtherCAT survey and motion-control migration.

Beckhoff and EtherCAT diagnosis

The engineering survey maps the Beckhoff PLC, NC task, EtherCAT topology, drive states and safety exchanges before migration. Each machine node is assessed because cable order, feedback format and motion behavior cannot be assumed.

Capture the EtherCAT tree, terminal types, servo drives and encoder interfaces.
Separate PLC interlocks from NC motion functions and laser-process signals.
Check cycle-sensitive devices such as height control, remote I/O and safety gateways.

Migration architecture

A suitable Bochu/CypCut architecture is designed around the machine's required axes and process interfaces; the existing EtherCAT arrangement is not copied blindly. Retained mechanical devices receive verified drive, feedback and I/O adaptation.

Create a replacement map for PLC, NC, drives, I/O and safety functions.
Define axis scaling, direction and homing from measured mechanics, not legacy assumptions.
Wire height control and laser process I/O through the new controller's approved terminals.

Commissioning and production acceptance

Commissioning first establishes predictable motion without laser power, then validates height response and cut sequencing. Production acceptance checks repeatability on the agreed geometry and documents any changed operating workflow.

Test each axis for direction, limits, homing and synchronized interpolation.
Validate interlocks, height-following response and process-output timing.
Run repeat contours and confirm dimensions, corners and operator recovery steps.

Typical Customer Challenges

01

A Beckhoff migration requires careful EtherCAT, PLC, NC and servo topology re-engineering.

02

Rising maintenance cost and unpredictable downtime

03

Need for higher power, easier operation or current process functions

Retrofit Engineering

Compatibility comes before configuration

Every project requires a machine-specific assessment. Final hardware, software and achievable performance depend on the existing mechanical accuracy, drive system, I/O, electrical cabinet, safety circuit and selected laser power.

A thorough engineering review confirms the retrofit solution is compatible, integrated correctly and sized around the real machine condition and production target.

Mechanical & electrical condition: Machine base, cabinet condition and safety readiness
Control, drives & fieldbus: Existing controller, drives, I/O and motion network
Target materials & laser power: Material, thickness, process target and proposed power

Assessment outcome

The review turns machine evidence into a clear engineering decision.

Feasibility confirmedIdentify the constraints that affect a retrofit path.
Scope definedSet the required controls, interfaces and safety work.
Commissioning plannedPrepare installation, parameter setup and handover.

Engineering review at a glance

Assessment Checklist

PLC, NC and EtherCAT topology surveyMachine base, cabinet condition and safety readiness
Motion, servo, fieldbus and I/O migrationExisting controller, drives, I/O and motion network
Laser source, cutting head and chillerMaterial, thickness, process target and proposed power
Electrical drawings and safety circuitMachine base, cabinet condition and safety readiness
Target materials, thickness and laser powerMaterial, thickness, process target and proposed power

Project Deliverables

Machine compatibility reportFindings and retrofit recommendations
Retrofit architecture and bill of materialsScope and component list
Electrical and I/O integration planWiring, signals and interfaces
Height control, cutting process and functional validationSetup and optimization
Operator training and handover recordsManuals and documentation
Remote support after commissioningOngoing technical assistance

Retrofit Engineering

From machine survey to production handover

01
Machine survey

Collect model, year, controller, source, drives, drawings and fault history.
02
Compatibility review

Verify mechanics, motion, I/O, safety, utilities and target laser power.
03
Retrofit engineering

Define control, optics, electrical, cooling, gas and safety integration.
04
Installation & commissioning

Install hardware, map I/O, tune motion and complete process parameter setup.
05
Training & support

Validate cutting samples, train operators, document the final configuration and provide post-commissioning support.

Retrofit Engineering

Selecting the right Bochu control platform

CypCut is a leading Chinese sheet-metal laser cutting software platform. Depending on power, motion architecture and process requirements, a project may use CypCut, CypCutPro or an EtherCAT-based FSCUT8000/HypCut solution.

Match the control platform to the installed laser power, motion architecture, I/O scope and the process control your production requires.

Installed power: Laser source and planned duty cycle
Motion & fieldbus: Existing drives, pulse control or EtherCAT readiness
Required process control: Everyday production, advanced functions or high-power coordination

Engineering fit check

Share your machine model, installed controller and production target. We review the practical control path before any retrofit scope is confirmed.

View Service

Platform fit at a glance

CypCut

Standard sheet cutting

For stable, day-to-day sheet-metal production on conventional motion systems, with practical programming and reliable operation for common cutting work.