Prima Power SHEAR GENIUS punching and shearing technology

Рrіmа The Bend
The Combi
The Laser
The Press
The Punch
The Shear
The System
The Software
Shear Genius new generation of integrated punching and shearing technology servo electric Shear Genius SG
Highest productivity with integrated punching and shearing The vast majority of all fabricated sheet metal components are rectangular, so a highly economical method to produce them is to perform first punching and
then shear the components loose in the same automatic process with an integrated right angle shear. Thirty years of experience in right angle shear technology combined with proven field performance in nearly 3,000 applіcations throughout the world has allowed providing Shear Genius with major benefits.

Servo electric Shear Genius benefits
Fast setup with up to 382 tools in a turret
30 Kn force for demanding products
Average power consumption
Power supply connection 
Low energy consumption at three power modes run stand by idle
Low maintenance cost
High versatility
High performance values
Automated flexible fabrication
No skeletons, less punching scrap savings in raw material
No nibble marks
Fast loading cycle with new loading device LD
Accurate pre cut raw material loading
Higher productivity
Reduced manufacturing costs                                          Faster return on investment
Wide range of options, can also be installed later as machine upgrades
Very high productivity in most varied applications

The shear Genius philosophy
The Shear Genius philosophy is to provide one machine capable of transforming parts to final production stages without the need for secondary operations for costly material handling between loading, punching, shearing, sorting and unloading. Shear Genius concept saves material, decreases necessary floor space and investment in separate machine tools, tooling and energy.
Today, right angle shear technology is used throughout the industrial world in most varied applications like panels, doors, HVAC, cabinets etc., also in independent
production cells, or as central units within automatic material handling systems up to a factory wide FMS level.
Here are some of the reasons why
Avoid the cost of preshearing
Pre shearing is a waste of time and money. Moreover, it is extremely difficult for a stand alone shear to achieve anything like the accuracy of components manufactured by an integrated right angle shear. Shear Genius can be fed with sheets up to 4,300 x 1,500 and direct from a coіlline.
Just the right edge quality
One stroke detaches one or several components. Micro jointed or nibbled components often require an additional work stage, such as deburring, to improve edge quality. A right angle shear produces sufficiently high edge quality for practically every purpose. The component is usually ready for the next work stage as it unloads from the machine. For example, there is no oxide layer on the edges to be removed before painting.
Practically no consumables
As for consumables, Prima Power's right angle shear technology uses only energy and compresed air. The blades have several cutting edges enough for years of production with an occasional sharpening. Blades, like punching tools, can be sharpened numerous times.The new shear also reduces 75 % of the maintenance time.
Don't pay for material you don't need
Compared with traditional methods, an integrated right angle shear can save significant raw material costs with continuous line nesting. The Shear Genius method
makes maximum use of material and eliminates micro jointed parts and further manual operations.
Automated solution
The modular design of the Shear Genius allows the addition of sorting and stacking equipment after the initial installation. The reliability of shearing and automatic component removal are inherent benefits of the right angte shear concept, and make Shear Genius the optimum machine tool for high level automation, unmanned operation and PSBB production line.

Shear Genius package
Automatic loading equipment 300 kN servo electric turret punch press
lntegrated right angle shear
Two models for standard size sheets max.
Two performance levels. 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 and automation. Servo electric high performance punching
An early and major step towards sustainable fabrication was taken on the introduction of the servo electric series turret punch press in 1998. Now Prima Power uses already the third generation of this technology.
Performance values are truly impressive
Hit speed up to 1,000 hpm
Sheet positioning speed up to 150 m min
index speed 250 rpm Max. 300 kN ram force for all functions and tools Multi Tool stations
The 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.
lmproved punching reliability
Optional hole check system improves reliability with advanced automation and unmanned 24 7 operations.
ECOPUNCH concept
Prima Power is the pioneer of servo electric punching.
The first punch press with the technique was introduced in 1998. Prima Power's ECOPUNCH concept is an astonishing money saver in terms of energy consumption. Compared to traditional method Prima Power can produce more parts at same energy.

Fast Auto lndex
A large number of index tools facilitates set ups and
programming, shortens tool change times and increases production speed. Maximum index rotating speed is 250 rpm. The rotation mechanism of the punch and
die is mechanically engaged and disengaged vertically. It enables full tonnage and punching speeds to be used in any station, with any tool size.

lntelligent ram
A new option is the Intelligent ram, which shortens tool change time and increases the number of tools in turret and especially that of index tools. Intelligent ram includes a rotating ram head, which enables old Multi Tool types to
Be used as indexable. Also new Multi Tool innovations such as 4A and 4B can be used with the new Intelligent ram. Up to 300 kN servo electric punching force can be selected for the ram. Automatic overload protection and central lubrication ensure dependable machine operation.

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 in height incl. sheet thickness. All forming tools are indexable and tapping
Fast component identification. There are several solutions for adding information to components to ensure reliable identification with different types of marking tools. Shear Genius can also be equipped with an inkjet or a labelling device.

Easy and versatile tapping
Further options include the servo operated
tapping unit TU6, an automatic six head tapping station and tapping monitoring system. Large tooling capacity
A totally re designed turret which can be customized and optimized for any requirement. Simultaneously, a recordbreaking number of 384 tools can be available in the turret thus unnecessary set ups can be eaѕіly avoided. The maximum number of index tools has also been raised to 128 The intelligent right angle shear
The Prima Power right angle shear is extremely fast in operation. Programmable blade height and automatic stroke depth adjustment optimize shearing. Blade speed is automatically selected for the maximum speed. Together with automatic shearing modes this optimizes operation speed. The intelligent right angle shear always allows using of the optimum solution for the stroke according to the part size to be made in each case, e.g.
a single stroke for shearing a 1,000 mm x 1,500 mm
component fast, multiple strokes in X direction up to maximum sheet length fast cut mode for shearing smaller components. The right angle shear can be used for mild steel. For stainless steel max. thickness is 3 mm.
Programmable sheet holder. The lateral forces caused by the shearing action are compensated using pneumatic sheet holders for excellent shearing quality and high tolerances. ln the right angle shear, sheet holders are programmable, allowing shearing close to forms.

Automatic blade clearance setting
Blade clearance adjustment is automatic. Machine control calculates the optimum blade clearance for materials of different thickness and the adjustment unit in the right angle shear automatically sets the correct clearance. This prolongs blade life and ensures high quality and burr free parts. Outstanding accuracy
As the right angle shear is an integral part of the ceil and not a separate machine, and since the sheet is firmly held throughout the fabrication process, high component
accuracy is achieved. Shear Genius accuracy reaches new levels through a new actuation mechanism for X and Y movement of the coordinate table. All machines are carefully tested before delivery. Support of large work pieces. When shearing large pieces an automatic lifting mechanism integrated in the conveyor holds the parts for high accuracy.

Intelligent part sorting
New shear has a unique system to sort parts and scrap.
If there are any trims or leftover on the sheet, it is sorted out through the shear frame and conveyor. lnside the shear, fast inverter driven conveyor system separate scrap and move the parts to sorting or stacking without any delay or waiting time. For scrap part sorting, metallic conveyor belt is now available on standard and also optional lifting conveyor. lmproved sorting conveyors having new inverter technology for faster sorting of components. Also, additional pallet changer, SU sorting unit can be installed to extend the part sorting addresses.

Long blade life time, engineer friendly setup
Shear blades are hardened tool steel with very long life time combined with automatic clearance setting. However, blades can be turned and reused since they have more than one cutting edge each. When all corners are used, blades can be sharpened and reused. With the new intelligent shear, blade maintenance time is 75 % shorter due to new shear construction and new remote control box for service engineer tests and adjustments.

Accessible
Shear Genius is operated with a modern control unit and its touch screen panel. Management of machine set up and work queues is easy with Tulus user interface.
The NC ExpressTM programming system and Tulus work іn perfect combination, provide comprehensive reports on machine and production status, and can be linked to the factory ERP system when required. Monitoring of machine operation is facilitated by four optional cameras that send image to the upper display. special attention has been paid to ergonomics and user friendliness of the control unit. Work orders created by NC Express es can be loaded to machine's task list easily by a bar code reader. TaskLoader system selects work orders from the data base automatically and adds them to machine's task list including all information on e.g. required NC programs, tooling and material needed in production. Further options to add accessibility include applications for handheld equipment. Tulus e Kanban, digital ordering process
Tulus e Kanban, despite its name, is not only replacing the Kanban cards but it also monitors the part ordering processes. Part's metadata is used to determine the batch size, storage location, where the order is placed etc. No special tools are required the bar codes can be read with a smartphone or a tablet. The order can go either to ERP or directly toTulus Power
Processing order management. The orders come in digitally, thus human errors are minimized since there is no loriger a need to update paper documents. Tulus e Kanban also monitors the process and tells the user if the parts are already ordered and in which work step the parts are currently going.
Tulus MUPS
To make the operator's work easier, a new Android based
Tulus MUPS application has been developed. It provides instructions for tool set ups and other operation tasks.
Sheet positioning. The machine features an axis actuation system based on maintenance free AC servo motors. The construction allows positioning speeds up to 150 m min acceleration of the axes is adaptive and accuracy excellent. Automatic clamp setting and moving
The Programmable Clamp Setting function automatically positions sheet clamps according to numerical program, minimizing clamp dead zones. When changing production from full size to small sheets, clamp settinigs can be made automatically without wasting operator time.

scratch free
Machine tables have been redesigned and equipped with more dense brushes, which together with the more solid table frame enable handling of sheets up to 250 kg in weight. A new option is having moving brushes also in front and inside of the turret and in front of the shear, which prevents effectively the scratching of sensitive materials.The movement is activated by the program when needed.

Modular automation
The flexible and modular Prima Power range of automa tion ensures the optimal way of material handling for extensive unmanned operation and thus lower production cost. Shear Genius is compatible with the whole range of optional material handling equipment for fast raw material feeding, sorting and stacking. Due to the wide range and modularity, the optimum solution can be found for every application and all system sizes. Automated part handting
Shear Genius with stacking system STS
Stacking solution with fast stacking address change
based on guided free fall part stacking. Guided free fall stacking. Fast stacking and address change
Up to two stacking wagons
Multiple stacking addresses
Shear Genius with picking and stacking robot PSR
Stacking solution with high flexibility based on accurate and gentle part stacking by gripper. Accurate and gentle stacking by gripper. Scratch free
Large stacking area up to four wagons and two stacking tables at the same time
Connection to panel bender

Shear Genius solutions can automate
Fast raw material availability                                          Raw material change in hidden time during machine operation
Sorting and stacking of components
Exit of components without interrupting machine operation
lntegration to next process steps such as bending
Storage connections

Shear Genius as a part of automated manufacturing line
PSbb with PCD
Compact PSBB manufacturing line for fully automatic manufacturing process dedicated for panel
production and door manufacturing.
Part buffering to conveyor Part stacking
External part feed to bending                                              Part turning before bending
PSBB with PSR
PSBB manufacturing line with high flexibility and large capacity of buffering and stacking components between punching shearing and bending process
Large stacking capacity
External feed of bent parts                                                  Part turning before bending
Balancing buffering between
punching shearing and bending process
Re organization of part flow before bending

Automated manufacturing Lines with storage solutions
Combo Tower with 90 degree connection by using rotating gripper of loading device LD
Combo Tower is a compact material storage enabling the availability of different materials whenever needed automatically and without delays. The Rotating gripper option of loading device LD enables more flexible placement of manufacturing lines to customer premises as required by production logistics.

Cut to length line and FL storage integration
FL storage is a process efficient solution when fast material changes are required due to production requirements. FL storage can deliver material to the machine cell in hidden time. NightTrain FMS with fast loading device FLD NightTrain FMS is a comprehensive solution for a sheet metal working factory designed for automated operation, where the main equipment is an automatic logistic centre. It can serve as material storage and as buffer storage for punched sheared and laser cut parts. Automatic storage enables long unmanned production times. With cut to length line integration remarkable savings in material usage can be achieved and machine utilization can be increased. Cut to length line can be used to feed material to the FL storage.

When fast material changes are required to machine cells, Fast loading device FLD can be placed between NightTrain FMS and machine cell. FLD picks up material directly from the cassettes on shelving unit and brings it to machine cell in hidden time without delays.

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. NC Express es programming system is a user friendly, integrated and automated tool for managing Prima Power equipment in the most efficient manner. As a scalable applіcation 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. 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

With Tulus Power Processing you can control the whole production process from order management, programming and machine time scheduling all the way to the fınished productand reporting.