Engineering takeaways
- Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain.
- A successful retrofit starts with measured machine condition and documented interfaces, not a controller shopping list.
- Retain a tested rollback path until safety, motion, process and production acceptance are complete.
Compatibility checklist
- Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain.
- Plan a machine-specific migration from an aging TRUMPF control path to a suitable Bochu platform by separating proprietary logic, reusable drives, process I/O and safety functions.
- Record machine model, serial number, year, working area and automation options.
- Identify controller, industrial PC, servo drives, encoders, fieldbus, remote I/O and height-control hardware.
- Collect electrical, pneumatic, gas, cooling, extraction and safety drawings; mark undocumented changes.
- Measure mechanical accuracy, backlash, gantry squareness, slat-bed condition and axis performance before increasing speed or power.
- Define materials, thickness range, assist gases, daily output, quality limits and target laser power.
Hardware and integration scope
- A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains.
- Document the rated interfaces and utilities named in the project scope: Plan a machine-specific migration from an aging TRUMPF control path to a suitable Bochu platform by separating proprietary logic, reusable drives, process I/O and safety functions.
- Industrial PC or operator console, controller and licensed software matched as one supported set.
- Servo/encoder interfaces, fieldbus couplers, remote I/O, safety relays and galvanic isolation where required.
- Capacitive height control, cutting-head signals, laser modulation, gas valves, chiller and extraction interlocks.
- Documented terminal numbering, cable shielding, grounding, spare I/O and service access for future maintenance.
Implementation workflow
- 01
Define the decision: Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain.
- 02
Capture the machine baseline: Plan a machine-specific migration from an aging TRUMPF control path to a suitable Bochu platform by separating proprietary logic, reusable drives, process I/O and safety functions.
- 03
Freeze the integration architecture: A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains.
- 04
Prepare the outage: A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains. Issue the retrofit architecture, I/O matrix, bill of materials, risk register, rollback plan and outage schedule.
- 05
Commission through controlled gates: Assuming proprietary modules are generic I/O can disable diagnostics, safety or machine automation. Commission axes at low speed, tune following error and height control, validate gas and laser signals, then build process tables progressively.
- 06
Prove production acceptance: Retained drives and automation must be tested under fault, recovery and production states—not only jog mode.
Detailed engineering notes
Decision boundary
Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain. Create a machine dossier containing model and serial data, photographs of nameplates and cabinets, electrical revisions, PLC and CNC backups, drive/encoder types, alarm history and sample parts. Record the current cut quality and cycle time so the retrofit has a measurable baseline.
Reusable assets and integration limits
A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains. The frame, gantry, rails, drives, motors, extraction, gas train and automation should be assessed independently. A part that powers on is not automatically suitable for higher acceleration, a different control loop or higher laser power.
Interface evidence
Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain. Identify controller, industrial PC, servo drives, encoders, fieldbus, remote I/O and height-control hardware. Industrial PC or operator console, controller and licensed software matched as one supported set.
Safety case
Assuming proprietary modules are generic I/O can disable diagnostics, safety or machine automation. Trace emergency stops, enclosure doors, light curtains, laser-enable chain, gas pressure, cooling flow, extraction and motion brakes. Each device needs a defined safe response and a recorded validation test after wiring changes.
Controlled commissioning
A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains. Verify power distribution and protective earth first, then I/O, fieldbus, axis direction, limits, homing, low-speed motion, servo tuning, height control, gas, laser enable and finally cutting. Do not combine first motion and first laser emission into one test.
Production proof
Retained drives and automation must be tested under fault, recovery and production states—not only jog mode. Use the customer's normal materials, thicknesses and quality criteria. Record nozzle, focus, gas, power, speed, piercing and inspection results, then compare repeatability across more than one sheet.
Handover and support
A common project question is: Is every TRUMPF machine suitable for CypCut? Engineering answer: No. Suitability depends on machine generation, mechanics, drive and encoder interfaces, safety architecture, automation and available documentation. Train operators on daily use and maintenance staff on backups, alarms, I/O diagnostics and safe replacement procedures. Store the final drawings and software image in at least two controlled locations.
TRUMPF Laser Control to CypCut Retrofit Guide
Plan a machine-specific migration from an aging TRUMPF control path to a suitable Bochu platform by separating proprietary logic, reusable drives, process I/O and safety functions. Document the existing controller-to-drive and controller-to-machine interfaces before deciding what can remain. A new Bochu stack may require new servos, height control, laser interface, operator console and cabinet wiring even when the frame remains.
- Is every TRUMPF machine suitable for CypCut?
- How is the TRUMPF safety chain proven after a CypCut migration?
- Which servo feedback and I/O terminals need a verified cross-reference?
- What tests release laser enable after the replacement cabinet is wired?
Risks and limitations
- Assuming proprietary modules are generic I/O can disable diagnostics, safety or machine automation.
- Treat an unresolved survey finding as a commercial and outage risk, not an assumption: Assuming proprietary modules are generic I/O can disable diagnostics, safety or machine automation.
- A new controller cannot correct worn rails, backlash, frame distortion or an unstable cutting bed.
- Bypassed or incompletely mapped interlocks create unacceptable personnel and equipment risk.
- Unverified licenses, firmware, servo compatibility or undocumented OEM logic can extend downtime.
Acceptance criteria
- Retained drives and automation must be tested under fault, recovery and production states—not only jog mode.
- Record the agreed evidence, limits and operator handover in the final acceptance file: Retained drives and automation must be tested under fault, recovery and production states—not only jog mode.
- All emergency stops, doors, light curtains, pressure, cooling and extraction interlocks stop hazardous motion or laser emission as designed.
- Axis travel, homing, limit switches, following error, repeatability and contour accuracy meet the agreed baseline.
- Cut coupons cover representative materials and thicknesses, including holes, corners, common-line cuts and piercing.
- Backups, drawings, parameter sets, licenses, spare-parts list, operator training and maintenance handover are complete.
Frequently asked questions
Is every TRUMPF machine suitable for CypCut?
No. Suitability depends on machine generation, mechanics, drive and encoder interfaces, safety architecture, automation and available documentation.
Can the final hardware be selected from photos alone?
No. Photos help identify the machine, but drawings, controller/drive data, I/O measurements, safety logic and mechanical checks are required before a binding scope.
How is retrofit downtime controlled?
Pre-engineering, cabinet preparation, software staging and acceptance planning are completed before shutdown. The schedule still includes contingency for undocumented wiring or failed legacy parts.
Official technical references
Platform names describe product families, not guaranteed retrofit compatibility. Final software, controller and license selection follows a machine survey.
