Esprit Automation Rotomax

A cope cut (or coped connection) removes a portion of the beam flange and web at the end of a beam to allow it to connect to the web of a supporting beam at the same elevation. For example, a secondary beam connecting to a primary beam of the same depth requires the secondary beam flange corners to be removed (coped) to clear the primary beam flange. The cope geometry removes material from both the flange face and the web side of the beam - requiring cuts on the flange top and bottom, the web face, and potentially the flange underside. On a flat-table plasma system, a structural section cannot be processed without complex fixturing and repositioning for each face. The Rotomax rotary torch orbits around the entire cross-section, cutting all faces in sequence without manual beam repositioning.

DSTV (Deutsches Stahlbau-Verband) is the German/European standard file format for structural steel component data exchange. DSTV files contain the complete machining information for a structural steel component: section profile, length, all drilling patterns (diameter, depth, tolerance), all cutting operations (cope details, angle cuts, notches), and material identification. Structural steel detailing software (Tekla Structures, SDS/2, Advance Steel, SCIA Engineer) exports DSTV files for each beam in a steel structure. The Rotomax CNC imports the DSTV file and automatically generates the plasma cutting program for all cope cuts and plasma operations on that beam. This eliminates manual NC programming - the operator verifies the imported program and runs production. DSTV import is the standard CNC structural steel workflow in European fabrication and is increasingly adopted in North America.

Yes, by plasma piercing - the plasma torch positions at the hole center location and pierces through the flange or web material, leaving a plasma-cut circular hole. For standard bolt holes (M20, M22, M24, M27) in structural steel: plasma piercing provides the hole in one step. Accuracy of plasma-pierced holes: typically +/-1.5 to 3 mm diameter from nominal, with a slightly tapered edge profile. For connections requiring Class A slip-critical bolt holes (tighter tolerance) or countersunk holes, plasma piercing requires reaming or sub-punching to clean up the hole edge. For shops where drilled bolt holes are required by specification, the Rotomax plasma piercing does not replace a drill - a drill/tap unit or separate drilling operation is required.

Esprit Rotomax vs Ficep Gemini: The Ficep Gemini is a complete structural steel processing line combining a multi-spindle drill head, saw, and coping unit on one automated line. The Gemini drills (Class A precision holes), saws, and copes H-beams in a single automated pass. Capital cost: Ficep Gemini $800,000-$2,000,000; Esprit Rotomax $150,000-$450,000. The Ficep is the appropriate choice for high-volume structural fabricators with full beam processing requirements (drill + saw + cope all in sequence). The Rotomax is appropriate for shops primarily needing cope cutting capability at lower capital cost, where drilling is handled separately. For shops where drilling is not required or is a small fraction of work, the Rotomax provides the cope cutting capability at a fraction of full-line cost.

The Rotomax is compatible with major plasma sources. Most commonly specified: Hypertherm XPR130 or XPR170 for precision structural cutting - the XPR provides the highest cut quality and squareness on thick flanges (40-50 mm). For lighter structural work (flanges to 25 mm), the Hypertherm Powermax 105 or 125 provides adequate quality at lower capital cost. ESAB and Lincoln Electric sources are also compatible with appropriate machine interface. Selection criteria: flange thickness of your heaviest structural section is the primary driver - for 40 mm+ flanges, a 130A+ source with good duty cycle (XPR) is appropriate; for predominantly lighter sections, a 65-105A source is adequate and more economical.