Combi Dresser-Changer Unit

The combined changer unites tip dressing and cap replacement in one compact system. Both processes are fully automated and perfectly synchronized. After each welding cycle, the electrode is re-dressed, and once the defined service life is reached, the system automatically replaces the cap.

New caps are loaded from a pre-equipped magazine, while used caps are automatically deposited in the collection container. Each magazine holds up to ten caps and can be refilled outside the cell, significantly reducing changeover time and minimizing production downtime. Both the dressing head and changer module are engineered for long service life and can be replaced separately.

The system was specifically developed for robot-guided resistance welding guns. Its robust and flexible design makes it suitable for production lines in steel and aluminum applications that require high cycle rates and frequent cap profile changes.

• Complete dressing and cap changing technology from one source
• Fully automated process for maximum system uptime
• Significant cost advantage over separate stations
• 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
• Suitable for various cap profiles and welding gun types
• Cap magazines are reloadable outside the cell
• Change 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.

Quick-Change System

Milling heads can be exchanged quickly using a quick-change system while maintaining full repeat accuracy. The system supports a range of milling heads and adapts flexibly to different electrode caps and welding guns.

Efficient Chip Removal

A pneumatic blow-off system removes chips directly at the machining point and transfers them to a sealed 3-liter collection container. The result is a clean working area and reduced downtime.

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.

Industry 4.0 Compatibility

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.