FAQ
Should I replace or upgrade my back gauge or just the CNC control?

CNC Control Retrofits for your Metal Fabricating Equipment

Frequently Asked Questions at PC Controls

How does PCC support their equipment after it is installed?

Why should I retrofit my machine?

Retrofitting your machine is a smart decision that offers numerous benefits, particularly in terms of cost savings, increased productivity, and seamless integration. If you're contemplating whether to retrofit or invest in a new machine, consider these three primary reasons why retrofitting is the superior choice.

Cost Savings

One of the most compelling reasons to retrofit your machine is the significant cost savings it offers. Retrofitting provides an economical alternative to purchasing a new or used machine tool. By choosing to retrofit, you can eliminate or minimize various expenses associated with acquiring new equipment, such as rigging and transportation costs, downtime, and the need for new investment in tooling and training. These savings can be substantial, allowing you to allocate your budget more effectively and invest in other critical areas of your business.

Furthermore, retrofitting ends the cycle of regularly pouring money into keeping an obsolete OEM CNC control functional. This is often the largest portion of maintenance costs for an otherwise useful machine tool. By updating your machine's control systems, you can significantly reduce maintenance expenses and ensure more reliable and efficient operation.

Increased Productivity

Retrofitting your machine can dramatically enhance the productivity of your fabrication team. Our priority is to ensure that our control solutions increase your operational efficiency. To achieve this, our software engineers have developed an intuitive graphical user interface that prioritizes a user-friendly experience. This means your team can quickly adapt to the new system, reducing the learning curve and minimizing disruptions to your workflow.

Our advanced control systems are designed to optimize machine performance, enabling faster and more accurate operations. This increased productivity can lead to higher output, improved quality, and greater customer satisfaction. By retrofitting, you can stay competitive in a demanding market and meet the growing needs of your clients.

Integration

Seamless integration is another significant advantage of retrofitting your machine. All our products run on Microsoft Windows operating systems, which allows for easy factory integration and service by a wide range of IT professionals. This compatibility ensures that your retrofitted machine can be easily incorporated into your existing factory infrastructure, simplifying the transition process.

Moreover, the use of a widely recognized operating system like Windows means that finding skilled IT professionals to service and support your equipment is straightforward. This reduces the risk of downtime and ensures that any issues can be promptly addressed, keeping your operations running smoothly.

In conclusion, retrofitting your machine offers substantial benefits, including cost savings, increased productivity, and seamless integration. By choosing to retrofit, you can extend the life of your existing equipment, reduce maintenance expenses, enhance operational efficiency, and ensure compatibility with your factory's IT infrastructure. Invest in retrofitting today and experience the advantages of a modern, efficient, and cost-effective solution for your machine tool needs.

What is covered in the on-site training when the machine is installed?

We provide a half of a day for training for your operators and maintenance personnel.  We will walk you through how to load new tooling, new materials and new parts into your new control.  We will train your operators on how to run you new control and your maintenance personnel on how to take care of your new control.

What if I have a problem after the new control is installed?

All new controls are warranted for 1 full year on parts and remove support is available for the life of your new control.  On-site field service is also available on a time and materials fee from PC Controls and from our authorized service representatives throughout the US.

How does PC Controls support their equipment after it is installed?

Our primary method of support is via online internet connection & phone support from our technical support staff. By supporting our customers with a remote internet connection and being able to speak with experienced machine tool & control technicians when your machine is experiencing a problem, you get the most cost-effective product support available. And our remote product support is available for the life of your control. 

What is the expected Return on Investment for a typical control retrofit?

    • This can vary depending on the type of machine tool and the type of fabrication operation involved.  Roughly you can expect to see an ROI of anywhere from 2 to 5 years.

What areas of efficiency and cost reduction can I expect if I upgrade my existing machine control?

  • General savings areas are:
  • A) Lower machine down time: B) Faster part creation and lower production time; C Cost savings associated with being able to integrate an older machine tool into your overall factory network; D) Lower control replacement costs.
  • Your PC Controls sales representative can help you with the cost justification process

What are some of the major benefits of a PC-based control retrofit?

  • Improved machine productivity and reliability
  • Off-the-shelf replacement parts
  • Advanced graphical features that enable greater productivity in programming and operation
  • A PC-based hardware platform running Windows software that allows for seamless machine integration into your overall factory/business environment

Can I replace my control system without replacing the other parts of my press brake?
Yes, you can replace just the control system on your press brake if the other systems are in good working order (mechanical, hydraulic, and electrical). We can help you determine which other areas, if any, on your machine need to be replaced so that you are only spending money where it is needed.  By investing your capital only in the areas that will benefit your operation you maximize your return on investment dollars.

Why should I upgrade the current control on my machine if it is still working?

Your machine tool may be working, but the question is: "Is it working to its max capacity & capability"?  Because of the rapid advances in control technologies, replacing the control on your machine can give the best 'bang for your buck' in improving the performance of your existing equipment. The mechanical, electrical and hydraulic systems on your machine tool do change, but computer control on machine tools is where the greatest technological strides are being made.  Therefore, it only makes sense to upgrade that part of your machine tool that can provide the most improvement of your fabricating equipment. 

Is my machine a good retrofit candidate?

A machine tool that is in overall good condition mechanically, hydraulically, and electrically, But has an unreliable CNC control that is problematic to support with OEM parts and maintenance service, is an ideal candidate for a cost-effective PC800 control retrofit.​

    What does it cost for a press brake control retrofit?

    Depending on the type of press brake you have and the features it has, a control upgrade can cost anywhere from $12,000 to $50,000. Even though control retrofits are not 'cheap', they can enhance your current equipment capabilities and are often a much more cost-effective long-term option than purchasing a new press brake, which can run as much as $500,000 and can often be very expensive in terms of rigging costs, training costs and all the other costs associated with bringing in a new machine tool. Give us a call and we will be glad to assist you with making the best decision for your company and your people. 

      Should a retrofit my current press brake control or purchase a new press brake?

      Depending on the type of press brake you have and the features it provides, replacing it with a new press brake can cost you as much as $500,000.  New press brake are not only expensive in terms of equipment cost, rigging costs, training costs and all the other costs associated with bringing in a new machine tool.  These cumulative cost of a new brake can add up to a very high price tag.  Newer press brakes do have many valuable features like 3-D graphics programming, automatic tooling and program generation and connectivity & integration, but many of these features can be also be obtained with a control upgrade. Give us a call and we will be glad to assist you with information to help you make the best decision for your company and your fabricating operation and you can get a good look at what our PC800 control retrofits can offer you.

        How does the retrofit process work?

        1. You email our team the details of your machine, along with a set of recent photos.
        2. Our engineering and sales teams work together to evaluate your machine and provide you with a quote for a suitable control upgrade solution.
        3. Once you place an order, a project manager is assigned and we begin the process of building your new control.
        4. Our engineering team designs a PC-based control upgrade solution for your machine tool with all its current functionality plus numerous new valued added features.
        5. Our production team assembles your retrofit and prepares it for shipment to your facility.
        6. An authorized PC Controls installer arrives on site and begins retrofitting your machine.
        7. When the install is complete, our installer will provide you with:
          1. Training for your team in the operation and maintenance of your new control
          2. Complete electrical and operational documentation
          3. A formal parts run-off, with your tooling and materials
          4. Setup of a programing station for off-line part programming, if desired
          5. In summary, our goal is that when our installer leaves the facility:
            • The operators know how to program and run the new machine control
            • The maintenance team knows how the control was integrated to your machine
            • We are well positioned to support operation of the new control for the life of your equipment
        8. It takes about 3-5 days to complete the retrofit and train your team, depending on the complexity of your machine.
        9. After install, we provide:
          • 1 year warranty on all new control parts
          • Aftermarket support over the phone and remote support over the internet that allows us to quickly assist you with resolving problems

          I've seen less expensive retrofits on other sites. Why is your retrofit more expensive?

          • Most of these "inexpensive" CNC retrofit controls are a generic package that must be integrated by the end user. Our PC-based retrofit package is a complete software/hardware system that requires no additional parts or programming.
          • Often "inexpensive" CNC retrofit packages require expensive engineering, programming and testing done by the end customer, integrator, or supplier. Often even more importantly, extensive machine down time can be associated with such packages often as there is little to no support available from the manufacturer during the installation.
          • Most of these packages are "one-size-fits-all" kits which are not customized to your unique control and machine needs. All PC Controls retrofit packages are specially designed and engineered for your make and model of machine and are integrated with its unique capabilities in mind.  Check us out and we'll show you why we think our PC800 control is the best option for you and your fabricating operation.

          What about software for the control? Do I have to purchase that separately?

          No. We always provide a matching software solution. It runs on the Microsoft Windows operating system family and is configured by our software team to best meet your needs and the capabilities of your machine tool.

            Do I have to change axis motors and amplifiers when I retrofit?

            In most cases, we can interface our control with your existing servo motors and amplifiers. If your machine servo system is reliable and able to be serviced for the future, we will use the existing equipment. If you desire an upgrade in this area, we do that regularly, and can provide a quote for optional equipment in addition to the CNC control.

            Should I replace or upgrade my back gauge or just the CNC control?

            The answer to this question depends on the overall condition of your back gauge and if it is meeting your fabricating needs. If the back gauge you have is in good working order or can be cost effectively repaired, then there is no need to replace it. If the back gauge does need to be replaced due to mechanical or other problems, then we can help with that. We offer Automec back gauges that come in different sizes and features to fit your needs. These gauge replacements are offered with options for X axis (gauge in & out) and/or R axis (gauge up and down). Give us a call (817-861-6955) or an email (info@pccontrosl.net) & we'll be glad to help. 

            How long will my machine be down during the retrofit?

            Most retrofits take a week or less (3-5 days) on-site, depending on the type of machine and control options requested. This time span includes operator and maintenance training.

            Will my machine tool work faster after a retrofit?

            • A PC-based control retrofit improves speed of operation and programming.
            • Many other productivity gains are provided, including Ethernet connectivity of your machine tool to your company network and unlimited part, tool, and material storage easily accessed through a Windows-based file storage system.

            Why retrofit your machine with PC Controls?

            • We are experienced
            • PC controls is the industry leader in retrofit fabrication CNC controls with more than 20 years of experience. Our company has a mature, reliable, field tested control with over 950 units operating in the US, Mexico and Canada. Click here to read more about the history and development of our controls.
            • Our controls exceed OEM functionality and features
            • Our control will be configured to work with your machine tool and is not a “one-size-fits-all" control. This means it can support features that your machine was designed with. Additionally, many of our customers enjoy the added functionality of new, value added features that that their old OEM control never included.
            • Industry leading supportWe understand from firsthand experience the frustration and headache that can arises from a machine tool suddenly slowing or stopping production and are committed to responsive aftermarket support.
            • We regularly provide troubleshooting recommendations on the first phone call and can often ship replacement parts the same day they are requested.
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