Electrode Cap Changer

The stationary cap changer automates the replacement of electrode caps directly on the welding gun. The gun positions itself autonomously at the changer station, where caps are removed and replaced with precision. Each magazine can hold either five or ten caps, depending on individual requirements.

New caps are loaded from a cap magazine that can be refilled outside the cell, reducing changeover times and downtime.

The changer system can be mounted directly on the dresser stand or on a separate support, depending on available space. When combined with a swing-in unit, the setup is implemented as a standalone module. For new installations, the combined changer with integrated dressing and changing technology is recommended.

• Proven in series production at international automotive plants
• Compact design for flexible integration
• Available in three installation heights
• High torque for 20 mm caps used in aluminum welding
• Cap magazine can be reloaded outside the cell with up to ten A/B/F/C-type caps
• Replaceable heads can be replaced quickly and easily

Control can be implemented either through a Variable Frequency Drive (VFD) or a control box. For different installation heights, a version with an adjustable stand is available. Additionally, versions with and without spring-based tong compensation are available.

Rotating System

The rotating changer gearbox removes electrode caps with a controlled rotational motion. Delivering torque up to 120 Nm, it reliably loosens even caps with tight press from the taper. Designed for cap sizes 13, 16, and 20, the system is also proven in aluminum welding applications.

Push-Off System

The push-off version removes electrode caps using a linear push unit. It is specifically designed for caps with press fits and is particularly suitable for plug-type shafts and eccentric caps where conventional pull-off systems reach their limits. Available in three installation heights, the system offers flexible integration into any production environment.

Mobile cap changers are used in systems with stationary swing arm units. They are mounted on the robot arm, which automatically positions the changer at the welding gun for cap removal and replacement.

New caps are loaded from a cap magazine that can be refilled outside the cell, reducing changeover times and downtime.

The compact design allows independent operation from the dressing system and ensures compatibility with systems from various manufacturers.

• Proven in series production at international automotive plants
• Compact design for flexible integration
• Available in three installation heights
• High torque for 20 mm caps used in aluminum welding
• Cap magazine can be reloaded outside the cell with up to ten A/B/F/C-type caps
• Replaceable heads can be replaced quickly and easily
• 14 kg total weight for flexible use at multiple workstations

Rotating System

The rotating changer gearbox removes electrode caps with a controlled rotational motion. Delivering torque up to 120 Nm, it reliably loosens even caps with tight press from the taper. Designed for cap sizes 13, 16, and 20, the system is also proven in aluminum welding applications.

Push-Off System

The push-off version removes electrode caps using a linear push unit. It is specifically designed for caps with press fits and is particularly suitable for plug-type shafts and eccentric caps where conventional pull-off systems reach their limits. Available in three installation heights, the system offers flexible integration into any production environment.

Sensor Monitoring
Integrated sensors continuously monitor the magazine fill level and confirm that each cap has been completely removed from the shaft after the change cycle. They also ensure that the robot can safely access the magazine during operation.

Industrie-4.0-Kompatibilität
Connectivity is provided via I/O modules with Profinet, either through fiber optic or copper connections. Alternatively, Ethernet/IP, Interbus, and other bus systems are available.
Process data is captured in real time and made available for automated operations or predictive maintenance. Optional RFID identification enables dressing head recognition.