TRUBEND press brake software modernisation: a successful CNC reverse-engineering project

Sespel specialists have modernised the software of a TRUBEND press brake. As part of a programme to improve equipment fault tolerance, engineers reverse-engineered its CNC system. The closed architecture of the overseas software had previously limited maintenance options. Static and dynamic analysis of the controller firmware restored the system’s full algorithmic logic. The project improved dynamic performance and diagnostics and produced structured documentation for adaptation to other machines.

Specialists from Sespel’s CNC design bureau have successfully completed a project to modernise the TRUBEND press brake software. The work formed part of a programme to improve the fault tolerance and technological independence of production equipment.

The central task was reverse-engineering the computer numerical control (CNC) software. The closed architecture and unavailable source code of the overseas proprietary software had previously limited maintenance, fault diagnosis and adaptation to new production tasks.

The company’s engineering team has now fully overcome this limitation. Specialists performed comprehensive static and dynamic analysis of the controller firmware, disassembled the control microcode and reconstructed the control system’s algorithmic logic, gaining full control over the machine’s functionality.

• Optimised dynamic performance. A longstanding issue with rapid traverse mode was resolved, improving positioning accuracy and reducing operation times.
• Extended diagnostic capabilities. Hardware monitoring was improved, with end-to-end real-time monitoring of digital input/output (I/O) signals to identify and locate faults quickly.
• A standardised, scalable solution. A structured set of software modules and accompanying technical documentation was created. This enables adaptation to other press brakes at the plant without major modifications.

The project establishes a technological foundation for the company’s full independence in developing and modernising industrial CNC systems. The expertise gained through reverse engineering will support maintenance of existing machines and the development of in-house control systems for future machine-building projects.

The TRUBEND modernisation further demonstrates Sespel’s engineering capabilities and its ability to address complex technical challenges relating to import substitution and the technological independence of production processes.