PLC Control Gabion Box Machine With Double Twisted Mechanism

A gabion box machine is a specialized industrial roll-forming system designed to produce double-twisted hexagonal wire mesh panels. These panels are later assembled into gabion baskets—widely used in civil engineering, erosion control, and architectural landscaping.

The machine typically includes an automatic decoiler (holding 2–4 wire coils), a wire straightener, a multi-stage roll-forming unit with progressive forming rollers, a double-twist mechanism, an automatic punching device for selvedge and diaphragm wires, a PLC-based control panel with HMI (human-machine interface), and a flying shear cutting system. It handles galvanized steel wire (often with PVC coating) ranging from 2.0 mm to 4.0 mm in diameter. Mesh openings are commonly 60*80 mm or 80*100 mm, with double-twisted selvedges to prevent unraveling.

The machine works on cold roll-forming and mechanical interlocking principles. Wire fed from coils passes through straightening rollers, then enters the forming zone where rollers progressively bend the wire into a zigzag pattern. Adjacent zigzag wires are twisted together through a rotating double-twist head—two full rotations per mesh cell. This creates the characteristic hexagonal shape with exceptional structural integrity. The twisting head operates synchronously with the panel advance speed. A punching unit automatically forms holes for binding wires between diaphragm panels and the main mesh. Finally, a flying shear cuts the continuous mesh to preset lengths (e.g., 2 m, 3 m, 4 m).

1. Wire preparation: Load galvanized/PVC-coated steel wire coils onto decoilers.
2. Straightening: Wire passes through horizontal and vertical straightening rollers.
3. Forming & twisting: Wire is shaped into zigzag and double-twisted with adjacent strands.
4. Edge reinforcement: The machine forms selvedge wires with extra twist for strength.
5. Punching (optional): Holes are punched at regular intervals for diaphragm connections.
6. Cutting: Flying shear cuts the continuous mesh into individual panels.
7. Stacking: Panels are automatically stacked and tied for packing.

Typical production speed: 80–150 m² per hour depending on wire diameter and mesh size.

• High automation: Only 1–2 operators required; PLC controls all parameters.
• Consistent quality: Uniform twist count (typically 3–5 twists per cell) and precise mesh openings.
• Material savings: Minimal waste due to accurate tension control and cutting.
• Versatility: Can produce different panel widths (up to 2.5 m) and lengths.
• Durability: Heavy-duty frame with hardened rollers ensures long service life.
• Quick changeover: Adjustable tooling for different wire gauges and mesh patterns.

Gabion baskets made by this machine are used for:

• Retaining walls and slope stabilization in highways and railways.
• Riverbank protection against scouring and erosion.
• Bridge abutments and drainage structures.
• Noise barriers along motorways (filled with stones).
• Landscaping: garden walls, decorative fences, and planters.

• Load wire coils following tension guidelines.
• Input panel length, mesh size, and twist count via the touchscreen HMI.
• Start automatic cycle; monitor the double-twist head for proper engagement.
• Regularly check sample panels for twist tightness and selvedge integrity.
• Perform daily lubrication of bearings, twisting heads, and cutting blades.

1. Wire quality: Use only wire with tensile strength ≤550 N/mm² (as recommended). Harder wire damages forming rollers.
2. Safety: Operators must wear cut-resistant gloves and safety glasses. Never touch moving twisting heads.
3. Maintenance: Clean forming rollers daily; wire fragments can cause jams. Replace worn cutting blades promptly.
4. Alignment: Periodically verify that wire straighteners are calibrated; bent wire leads to irregular mesh.
5. Electrical: Keep control panel dry and away from water; use voltage stabilizers.
6. Startup check: Before production, run a dry cycle to ensure no debris in the twisting mechanism.

In summary, the gabion box machine is a reliable, high-efficiency system that transforms low-cost steel wire into durable mesh panels for critical infrastructure and green construction projects. Proper operation and regular maintenance ensure decades of service