How to Change Hexagonal Mesh Size (80x100 to 100x120) Without Distorting Hexagons

For operators of hexagonal wire netting machines and gabion mesh machines, changing the mesh size—for example, upgrading from an 80x100mm to a 100x120mm specification—is often the most dreaded task.

While the basic concept of swapping molds and gears seems straightforward, the reality is that many new operators are left scratching their heads when the machine restarts and begins producing irregular, lopsided hexagons. Online manuals rarely provide a sequential troubleshooting guide for this exact issue.

At Candid Equipments, we understand that downtime is lost money. In this guide, we break down the exact mechanical procedure for changing your mesh size and provide a step-by-step troubleshooting sequence to ensure perfectly symmetrical wire meshes every time.

Step 1: The Exact Mechanical Procedure for Changing Mesh Size

Changing from an 80x100mm to a 100x120mm mesh requires a complete swap of the twisting mechanism components and a recalibration of the machine's stroke.

1. Safety First & Wire Removal: Power down the machine, engage the emergency stops, and cut/remove the existing wire feeds from the twisting zone.

2. Remove the 80x100mm Molds: Unbolt and carefully slide out the current pinions (twisting gears), rack gears, and half-gears.

3. Install the 100x120mm Molds: Insert the new set of pinions designed for the 100x120mm mesh. Crucial detail: Ensure that the timing marks on the gears align perfectly. A single tooth misalignment here is the leading cause of distorted meshes later.

4. Adjust the Rack Stroke: The 100x120mm mesh is larger, meaning the machine requires a longer mechanical stroke to pull and twist the wire correctly. Adjust the eccentric wheel or the servo drive stroke settings to match the 100x120mm specifications.

5. Reset Wire Tensioners: A larger mesh hole requires slightly different wire feeding tension. Loosen the spring tensioners on the wire payoff stands before threading the new wire.

Step 2: Troubleshooting Irregular and Lopsided Hexagons

So, you have successfully swapped the molds to 100x120mm, but the machine is spitting out uneven, lopsided hexagons. Instead of blindly turning wrenches, follow this exact troubleshooting sequence:

1. Check for Uneven Wire Payoff Tension (The Most Common Culprit)

Lopsided hexagons almost always occur when the left wire and the right wire are entering the twisting pinion at different tensions.

• The Fix: Inspect your wire spools and spring tensioners. If the line wire is pulled tighter than the winding wire, the twist will naturally pull to one side, skewing the hexagon. Calibrate the tension so both wires feed with identical resistance.

2. Verify Pinion Gear Timing

If your mesh looks consistently "staggered" across the entire width of the machine, your gears are likely out of sync.

• The Fix: Manually rotate the machine using the handwheel (or jog mode). Watch the pinions as they grab the wire. They must close and rotate at the exact same millisecond. If one side grabs earlier than the other, you must unbolt the rack, realign the pinion teeth, and lock it back in.

3. Inspect the Stroke Length Recalibration

If the hexagon is symmetrical but looks too "squat" or too "elongated" (e.g., it looks like 100x110mm instead of 100x120mm), the twisting stroke is incorrect.

• The Fix: Go back to the eccentric wheel adjustment. If the mesh is too short, increase the stroke length slightly. Make micro-adjustments of 1-2mm and run a test meter of mesh.

4. Check for Worn Spring Coils or Guide Tubes

Sometimes, the new 100x120mm molds are perfect, but the older guide tubes feeding the wire have grooves worn into them from the previous 80x100mm production run.

• The Fix: Check the wire entry points. If the wire is catching on a burr or a worn groove, it creates micro-stutters in the feed, resulting in random lopsided holes. Replace the worn guides.

Why Choose Candid Equipments?

Mastering the mold change is essential, but operating a poorly engineered machine will always result in constant adjustments. At Candid Equipments, our heavy-duty gabion mesh machines are CNC-machined for precise tolerance.

Our machines feature quick-change gear designs and integrated tension equalization systems, drastically reducing the headache of changing mesh sizes. Whether you need standard netting or complex gabion box setups, our equipment ensures high yield with minimal scrap.

Looking to upgrade your wire mesh production line? Explore our full range of machinery on our Alibaba Storeor our Made-in-China portal.