Prima Power Combi Genius

Combination machines eliminate the material handling step of moving sheets from a punch press to a laser cutter between operations. This provides: (1) single-setup production of complex parts with both punched and laser features; (2) elimination of a second machine investment and the floor space it occupies; (3) reduced work-in-process inventory between punch and laser operations; (4) single programming effort for the full part in one combined machine program. The combination works best for parts that genuinely need both processes — punched formed features (louvers, embossing) that lasers cannot make, plus laser-cut profiles that would require hundreds of nibbling hits with a punch press.

Servo-electric punch presses use a high-torque servo motor driving a mechanical ram (via cam, crankshaft, or ballscrew mechanism) instead of a hydraulic cylinder to generate punching force. Advantages: (1) energy efficiency — servo-electric only uses energy during the punch stroke, not continuously like hydraulic pumps; (2) quiet operation — no hydraulic pump noise, significant noise reduction; (3) programmable stroke depth — the servo can stop at any position, enabling embossing, half-shear, and depth-controlled forming; (4) faster repositioning response — servo drives react faster than hydraulic valves. Disadvantages: lower maximum force than large hydraulic machines; servo motors and drives are complex and require specialized service.

The 48-station turret holds Amada-compatible (or Prima Power) punch and die tooling including: round punches and dies for hole punching in many diameters; rectangle, oblong, and square tools for non-round holes; forming tools for louvers, bridges, half-shears, and embossed logos; tapping tools for in-machine tapping of punched holes; countersinks for screw clearances; marking stamps for part identification; and nibbling tools for profile cutting. Tools are loaded into the turret and selected automatically by the CNC program. Turret management software tracks tool positions and wear.

For punching: mild steel up to 6.35 mm, stainless steel up to 4 mm, aluminum up to 6.35 mm. For laser cutting: mild steel up to 8 mm, stainless steel up to 5 mm, aluminum up to 4 mm, copper and brass at thin gauges. The machine cannot punch or laser materials that are too thin (below 0.5 mm) without special tooling adaptations, and very thick material (above the stated limits) will either damage tooling or produce poor quality cuts. Material flatness is critical for both punching and laser accuracy — warped or heavily oiled sheet should be flatttened before processing.

Night Train FMS (Flexible Manufacturing System) is Prima Power's automatic storage and material handling system that can be connected to the Combi Genius (and other Prima Power machines) for lights-out production. The Night Train stores raw sheet material in a vertical tower storage system and automatically delivers sheets to the machine's loading position, loads them into the machine, and collects completed parts and skeleton scrap after processing — all without operator intervention. A single operator can set up jobs during day shift; Night Train runs those jobs automatically through the night. The system requires planning during machine specification and cannot be retrofit-installed on machines not originally configured for FMS integration.