The new Laser Genius+ 2D machine from Prima Power shapes the new era of laser cutting
The Prima Power range of 2D machines has been further enriched with the addition of the new Laser Genius+, which has been designed and developed to meet the needs of a constantly evolving market, setting new standards in speed, reliability and precision.
The new Laser Genius+ 2D fiber laser machine - completely designed and built in Italy - has been developed using Prima Power’s experience of over 40 years in the industry and an extremely pragmatic approach, aimed at satisfying real market expectations. This requires greater performance, efficiency, quality, ease of use, automation and intelligence.
With a trajectory speed of 180m/min, the Laser Genius+ is one of the fastest and most productive machines on the market. Most importantly, the machine has been designed to make the very most of its available laser power.
The Laser Genius+ machine family includes 1530, 2040 and 2060 size models and can be equipped with a wide range of fiber laser power options, from 2kW up to 15 kW. The machine is designed to have total control over the laser process and to obtain maximum reliability and quality with all of the power available. To take advantage of the high power capability, a fast, rigid and light machine is needed. In the same way that a vehicle is designed, pure power alone is not sufficient to gain high performance, other elements such as the suspension, structural rigidity and light weight are all significant factors. This same principle applies to laser machinery - to reduce cycle times, an excellent relationship between the rigidity of the frame and the weight of the moving masses is highly important. It is precisely these features that allow the Laser Genius+ to squeeze out every ounce of power at all times.
The new laser head on the machine has been designed to optimally manage the heat required to melt thick materials whilst staying cool and clean. This is achieved thanks to sensors that actively control the cutting process in real time, hermetically isolated optics, simplified mechanics, and a high efficiency fume extraction system.
A further important bonus of the machine is its unique layout, which has been designed to ensure superior ergonomics and ease of use, as well as to make the most of the space that the machine occupies.
Accessibility has always been a distinctive feature of Prima Power machines and this is even more so for the Laser Genius+. The cabin is available with large sliding doors that can be placed on the right, left, or even on both sides of the machine, for maximum ergonomics.
Its footprint - one of the smallest on the market - and the simplicity of the layout, which integrates all of the services into one dedicated module separated from the working area, make the machine an extremely compact, plug & play system with very quick installation times - the Laser Genius+ only takes two days to be installed and start work. Additionally, the symmetrical and reversible layout means that the machine can be placed in any production context, without limiting process flow.
Despite its compact layout, the Laser Genius+ has the largest working area when compared to alternative machines that are available. X, Y and Z axis strokes are 3,150 x 1,600 x 150 mm respectively for the 1530 model and 4,320 x 2,200 x 150 mm, for the 2040.
The new Prima Power fiber laser head on the machine is designed for excellent cutting quality and dynamics on all materials and processable gauges, with laser powers up to 15kW.
The head boasts adaptive optics for the automatic management of the focal position and diameter and a fast, reactive and precise measurement of the stand-off from a single focusing lens suited to all production requirements. This is complemented with a Side Impact Protection Systems (SIPS), Optical Precision Control (OPC) and a protective glass drawer for easy inspection.
On the Laser Genius+, advanced monitoring systems are in place to check the entire process. For example, LISA (Light Intensity System Analyser) checks the correct operation of the process parameters in real time and the Check Optics function allows the management of the protective glass maintenance, thereby minimising downtime.
The machine optionally features Tech Suites that ensure a further reduction in cycle times whilst also offering superior quality, thanks to the intelligent management of head movements and the piercing and cutting parameters. The new, 20 station automatic nozzle changer allows the operator to have the most suitable nozzle available for the process at all times.
Additionally, the Laser Genius+ is the smartest and most interconnected machine that Prima Power has ever produced, with a very high degree of connectivity, new laser head sensors and artificial intelligence algorithms for advanced process monitoring and control features.
The machine can be integrated with other systems and management software, thus maximising efficiency and productivity. The software manages all phases: importing production orders generated by the customers’ system, automatic programming with Prima Power CAMs, production planning and creation of work lists to be loaded directly onto the machine, and the collection of machine production data (pieces produced, materials used) and performance information (machine status, alarms, processing times) to provide all of the data necessary for production control management systems - all fully compliant with Industry 4.0 requirements.
Prima Power has always been a long-term partner with its customers throughout the product life-cycle, and as such solutions have been developed based on the concept of the Internet of Things from a SAAS (Software As A Service) perspective. This solution is dedicated to the monitoring and advanced diagnostics of a large amount of behavioural, non-production data collected by the Laser Genius+. The information is collected within a certified cloud for security and is available to technicians at Prima Power Service Centres, who can check the behaviour of the machine via a Remote Care web application and give customers suggestions to improve production and help resolve any unexpected problems.
A new 24” high-definition dual monitor console and simplified user interface have also been designed for the Laser Genius+. The Information Panel on the machine also displays data such as details of processed materials and energy consumption in real time - highly useful for operators and production managers.
The machine is also equipped with three new, on-board software modules: Optia - for the recovery of scrap sheets by digitising shapes via the camera, thereby reducing waste; Wizard - a simplified CAM that allows the creation of new nests and processes, or the modification of existing ones by moving, rotating and deleting pieces; 2D Editor, a part program graphic editor that allows adjustments to the technology such as manual and automatic cutting, lead-in and micro-joints.
The Laser Genius+ is designed for continuous, 24/7 production and included as standard is an automatic, fully electric pallet changer with up to 30% reduced cycle times compared to previous versions. In view of the increased dynamic performance of the machine and the optimal exploitation of high-power fiber lasers, the Laser Genius+ is an excellent match for a wide range of automation solutions that cover all production needs, including unmanned operation. The machine can be easily connected to Prima Power automation systems to automate the flow of material and machined parts - loading, unloading, picking, stacking, and storage - and further increase productivity. The automation modules can also be integrated separately and at a later date, as production volumes grow.
A number of automation options are available, starting with the Compact Server - the most compact layout solution on the market. Affordable and easy to use, this solution is suitable for short periods of unattended operation where a production mix is not required. With the addition of a third pallet, it is possible to load and unload both from a manual station and from the automation, ensuring high production flexibility. Alternatively, the Combo Tower Laser is available with 1 or 2 multi-functional and configurable towers which are an optimal solution for small to medium, ‘lights-out’ production volumes. For high volume requirements, the Night Train is a flexible manufacturing system that automates the entire manufacturing process in a single step, from scheduling through to production reporting in 24/7 production environments.
The Laser Genius+ has all the winning elements of Prima Power machines, but perfects them and brings them even closer to the customer needs, offering excellent levels of productivity, quality and efficiency, while also guaranteeing maximum ergonomics and ease of use for the operator.
