Combi Genius

Combi Genius punching – laser cutting cell introduces a new generation of servo-electric punching technology. Enhanced productivity is complemented by a totally new industrial design.
  • High productivity due to versatility – “four-in-one”
  • Punching, forming, marking, laser cutting – even bending; high speeds, ease of operation, minimum set up times
  • A new Intelligent ram shortens tool change time and increases the number of tools in turret
  • Small and compact layout even with automation modules
  • The laser can also be used for cutting materials like copper or brass
  • Small power supply connection and very low energy consumption due to servo-electric punching and fiber laser cutting technologies
  • Inherently low maintenance cost
  • No laser gas required
  • High tooling capacity = fast setup and less waiting time
  • Less energy = less CO2
  • No hydraulic oil = no hazardous waste
  • Lower heat and noise emissions = better for the operator and for the environment
  • Less maintenance = increased productivity
  • One cell instead of separate machines = smaller space requirement

Three models: CG1225, CG1530 and CG1540

  • Max sheet size
    CG1225: 2,500 mm x 1,250 mm
    CG1530 / X25: 3,000 mm x 1,250 mm
    CG1530 / X30: 3,000 mm x 1,500 mm
    CG1540: 4,300 mm x 1,500 mm
  • Max. sheet thickness: 8 mm
  • Customized turret
    Max. tools in turret: 384
  • Max. index tools in turret: 128
  • Laser power: 3 kW or 4 kW
  • Max. sheet thickness, punch and laser: 8 mm (Al, Mild steel, Stainless steel)

Two performance levels: Pure and Dynamic

P-PURE & D-DYNAMIC
The new Genius series has models on two complementary performance levels. Pure meets all the targets set for an attractively priced, yet efficient production machine; Dynamic offers the best productivity and performance in the market. Both models come with the latest features and can be equipped with the whole range of options.

  • Ram force, max.
    CG Pure: 230 kN (25 US Tons)
    CG Dynamic: 300 kN (33 US Tons)
  • Hit speed, max.
    CG Pure: 700 hpm
    CG Dynamic: 1,000 hpm
  • Positioning speed
    CG Pure / X25: 108 m/min
    CG Pure / X30: 127 m/min
    CG Dynamic / X25: 127 m/min
    CG Dynamic / X30: 150 m/min
  • Index tool rotation speed
    CG Pure: 180 rpm
    CG Dynamic: 250 rpm

State-of-the-art fiber laser cutting

A modern combi machine uses numerically controlled, servo-electric axes, which provides outstanding energy efficiency, low maintenance requirement and a high speed of operation. The cornerstones of its productivity include large tool capacity, the wide range of tools available and easy and fast set-up change. As the best laser power source for the combi machine, the genuine fiber laser has a very high efficiency. Its highest utilization degree is conveniently suitable for material thicknesses less than 8 mm designed for the machine. Forming and other auxiliary work stages and ease of use are further factors reducing the manufacturing cost per component thus making the combi machine a productive and competitive manufacturing solution.

Combi Genius combines the benefits of this punching performance with the latest in fiber laser cutting, raising the productivity of the highly versatile integrated manufacturing concept to a new level. As the laser source, a fiber resonator of either 3 kW or 4 kW can be chosen. The optimized cutting head, collimator, transfer fiber and cutting parameters ensure a very high cutting quality and speed.

Easy cover protection system

Easy cover protection system around the machine is especially designed for the requirements of the combi machine. This provides protection from any scattered radiation of the fibre laser, but allows loading, unloading and maintenance procedures for the operator as easily as possible.

Combi Genius with Compact Express

No setups

Unbeatable tooling concept by Prima Power is a time saver – no extra stops for tool changes, no setups – all tools are active for immediate use.

  • SG turret with Prima Power toolsCustomizable turrets
  • Compatible with different tool manufacturers
  • Multi-Tools®
  • Index tools
  • Intelligent ram

Large tooling capacity in active use

A totally re-designed turret which can be customized and optimized for any requirement. Simultaneously, a record-breaking number of 384 tools can be inserted in the turret. The maximum number of index tools has also been raised to 128.

Turret examples

20 hole turret: customer specific layout with 81 tools, of which 25 index tools.
16 hole turret: customer specific layout with 79 tools, of which 39 index tools.

Click the image to enlarge.

Intelligent ram

Intelligent Ram 3DIntelligent ram is a rotating ram head which shortens tool change time and increases the number of tools in turret and especially that of index tools. Up to 300 kN servo-electric punching force can be selected for the ram. Automatic overload protection and automatic central lubrication ensure dependable machine operation.

Video

Multi-Tool® – turret in a turret

3 different Multi-ToolsThe turret can be equipped with Multi-Tool® stations to increase the number of tools. The latest development in Multi-Tool® technology is the possibility of using drop-in style indexable Multi-Tools® on D-size index tool holders.

More value to parts with special tools

High upforming

An additional forming cylinder is available. It is a servo-operated ram installed in the lower machine frame. It lifts the forming die to a programmed position. The cylinder provides 200 kN forming power for speedy making of complicated forms up to 16 mm (0.63″) in height (incl. sheet thickness). All forming tools are indexable.

Video


Fast component identificationMarking samples w550

There are several solutions for adding information to components to ensure reliable identification with different types of marking tools. Combi Genius can also be equipped with an inkjet marker or a labelling device.

Easy and versatile tappingMultithread and sample

Further options include the servo-operated tapping unit TU6, an automatic six-head tapping station and tapping monitoring system.

Video

Reliable laser cutting

The optimized cutting head, collimator, delivery fibre and cutting parameters guarantee the highest cutting quality and speed for the Prima Power combi machine in the market. The high-quality and powerful fibre laser is available either with 3 kW or 4 kW Prima Power CF resonator.

Combi Genius includes many safety systems to improve cutting performance and reliability. Lens protection window LPW prevents dust and spots on the lens. Laser plasma monitor LPM follows the cutting process and restarts it if necessary. Lens condition sensor LCS follows lens condition and informs the operator when lens requires changing.

For the laser-cut parts, two drop doors are provided as standard; 300 mm x 400 mm for quicker sorting and 800 mm x 800 mm for larger parts. New brushes on the chute top prevent scratches.

From the drop door, the parts are transferred by conveyor to the side of the machine to be unloaded manually or forwarded with different conveyor and sorting solutions.

Accessible

Tulus® GUI

Combi Genius is operated with a modern control unit. Management of machine set-up and work queues is easy with Tulus® user interface.

Digital ordering process

Prima Power has developed more software to ease both operator’s work and order management. TaskLoader, Tulus MUPS and Tulus e-Kanban are lightweight applications which, depending on the app, communicate with the machine and ERP and can be used with a smartphone or tablet.

TaskLoader-eKanban-MUPS (w1100h312)

Proprietary software

Special attention has been paid to ease of machine setups and efficient programming. The benefits include excellent possibilities for e.g. roll forming and for other special tooling. With optional features, the software can be made compatible with standard ERP connections for importing orders and exporting reports.

nxexpress-banner

NC Express e3 programming system is a user friendly, integrated and automated tool for managing Prima Power equipment in the most efficient manner. As a scalable application it can be used as a single part drafting and tooling program or as a fully automatic machine tool programming system. Either way the results are the same – optimized automatic NC-code creation.

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tulus-banner

Tulus® is management software of fabrication machines and systems. Tulus® controls machines with all essential information on machine related tasks within the same window. On arrival of new orders, Task management informs the operator of eventual needs for changes in materials, tooling, etc. Tool setting and other machine parameters can be easily set by interactive graphical interface. Additional production scheduling performance reporting and remote monitoring are available.

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sheet floating system

Scratch free parts

Sheet floating system prevents effectively the scratching of sensitive materials. The movement is activated by the program when needed and special scratch free punching mode is available.

Brushes up = sheet moving

Brushes down = sheet processing

Compatible automation

green_means__additional_artworks_640x480Green means® – more profit with smaller footprint

Green means a win-win for you and sustainable development.
Sustainability adds to manufacturing efficiency and productivity.
Your customers, your employees and the community you operate in demand it more and more.
Sustainability and social responsibility are characteristics of a modern company and add to competitiveness.
They make a difference between the best and the rest.
And you make better sheet metal components at lower cost.

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