Choosing Drives & Servos That “Play Nice” With Your PLC Platform in Roll Forming Machines

Introduction — Why Drive and PLC Compatibility Matters

Roll forming machines rely heavily on motor drives and servo systems to control motion throughout the production line. These components control the speed, torque, and position of machine elements such as forming rolls, flying shears, punching units, and material handling equipment.

Although many drives can technically operate with many PLC platforms, choosing components that integrate well together significantly improves system performance, reliability, and ease of troubleshooting.

Drive and servo compatibility affects several critical aspects of machine operation:

• communication reliability
• motion control precision
• commissioning complexity
• diagnostics and troubleshooting

Selecting drives that “play nicely” with the PLC platform ensures the automation system operates smoothly and can be maintained easily throughout the machine’s lifetime.

Types of Drives Used in Roll Forming Machines

Roll forming machines typically use two main categories of motor control systems.

Variable Frequency Drives (VFDs)

VFDs control the speed of standard induction motors.

Typical applications include:

• main roll forming drive motors
• coil feed systems
• auxiliary motors

VFDs allow operators to adjust machine speed while maintaining stable torque output.

Servo Drives

Servo drives control servo motors that provide precise position and speed control.

Servo systems are commonly used in:

• flying shear carriages
• servo feed punching systems
• positioning systems

Servo drives provide accurate motion control and rapid response times.

Why PLC–Drive Compatibility Matters

Drives and PLCs communicate through industrial networks and control signals.

If the communication interface is not optimized for the PLC platform, the machine may experience:

• communication delays
• difficult configuration
• limited diagnostic information
• synchronization problems

When drives and PLC systems are designed to work together, integration becomes easier and system performance improves.

Integrated Automation Ecosystems

Many automation manufacturers produce both PLC systems and drive systems designed to operate together.

Using integrated ecosystems provides several advantages.

These include:

• simplified configuration
• improved diagnostics
• faster communication
• better technical support

Examples of integrated ecosystems include:

PLC platform paired with compatible drives.

Siemens PLCs and Siemens Drives

Roll forming machines using Siemens PLC systems often use Siemens drives.

Common drive families include:

• SINAMICS VFD drives
• SINAMICS servo drives

These drives integrate directly with Siemens PLC platforms using PROFINET communication networks.

Benefits of this integration include:

• simplified configuration through TIA Portal
• integrated diagnostics
• reliable high-speed communication

This combination is common in European roll forming machines.

Allen-Bradley PLCs and Rockwell Drives

Machines using Allen-Bradley PLC platforms often use drives from Rockwell Automation.

Typical drives include:

• PowerFlex VFD drives
• Kinetix servo drives

These systems communicate using EtherNet/IP networks.

Advantages of this combination include:

• seamless integration with Studio 5000 software
• advanced diagnostics
• strong support in North America

Many American roll forming machines use this automation ecosystem.

Mitsubishi PLCs and Mitsubishi Drives

Many Asian roll forming machines use Mitsubishi automation systems.

Typical drive systems include:

• FR-series VFD drives
• Mitsubishi servo systems

These drives integrate with Mitsubishi PLC systems through industrial communication networks.

Advantages include:

• simple configuration
• reliable motion control
• good compatibility with Mitsubishi automation hardware.

Omron PLCs and Servo Systems

Omron PLC systems frequently integrate with Omron servo drives.

These systems typically communicate using EtherCAT networks, which provide extremely fast communication for motion control.

Advantages include:

• high-speed servo synchronization
• deterministic communication
• integrated motion control tools

This architecture is often used in high-performance automation systems.

Beckhoff PLC Systems and EtherCAT Drives

Beckhoff automation platforms typically use EtherCAT-based drive systems.

EtherCAT communication allows:

• extremely fast data transfer
• precise multi-axis synchronization
• real-time motion control

These systems are frequently used in high-speed roll forming machines that require precise flying shear control.

Delta PLC Systems and Delta Drives

Entry-level roll forming machines often use Delta automation systems.

Typical drive combinations include:

• Delta VFD drives
• Delta servo systems

These components integrate well with Delta PLCs and provide reliable performance at a lower cost.

However, these systems may have fewer advanced motion control features compared with premium platforms.

Communication Protocol Compatibility

Drive systems communicate with PLCs using industrial networking protocols.

Common communication networks include:

• PROFINET
• EtherNet/IP
• EtherCAT
• Modbus

Selecting drives that support the PLC’s preferred network protocol simplifies system integration.

Communication compatibility is essential for stable machine operation.

Motion Control Requirements in Roll Forming

Roll forming machines often require precise synchronization between moving machine components.

Examples include:

• flying shear synchronization
• servo punching operations
• automated positioning systems

These applications require drives capable of responding quickly to PLC commands.

Servo drives must provide accurate feedback to maintain synchronization.

Drive Diagnostics and Monitoring

Advanced drive systems provide diagnostic data that helps engineers troubleshoot machine problems.

Important diagnostic information includes:

• motor speed feedback
• torque levels
• drive fault codes
• communication status

Drives that integrate well with the PLC platform allow this information to be displayed on the HMI.

This improves troubleshooting efficiency.

Commissioning Drives with PLC Systems

Commissioning motor drives requires careful configuration.

Typical commissioning steps include:

1. configuring communication networks
2. setting motor parameters
3. testing drive operation
4. tuning motion control parameters
5. verifying synchronization with machine processes

Proper commissioning ensures stable machine operation.

Preventative Maintenance for Drive Systems

Routine maintenance improves drive reliability.

Recommended maintenance practices include:

Monthly inspections:

• check drive cooling systems
• inspect communication cables

Quarterly inspections:

• review drive diagnostic logs
• verify motor performance

Annual maintenance:

• inspect wiring connections
• verify grounding systems

Preventative maintenance helps prevent unexpected drive failures.

Benefits of Choosing Compatible Drives and PLC Systems

Selecting drives designed to work with the PLC platform provides several advantages.

These include:

• simplified system configuration
• faster commissioning
• improved diagnostics
• better long-term support

Integrated automation systems improve reliability and simplify maintenance.

FAQ — Choosing Drives and Servos for PLC Systems

Why should drives match the PLC platform?

Matching drives with the PLC platform simplifies configuration and improves communication reliability.

Can different brands of drives work with a PLC?

Yes, but integration may require additional configuration and may not provide full diagnostic capabilities.

What communication networks are used between PLCs and drives?

Common networks include PROFINET, EtherNet/IP, EtherCAT, and Modbus.

When should servo drives be used instead of VFDs?

Servo drives are used when precise positioning or synchronization is required, such as in flying shear systems.

Are integrated automation ecosystems better?

Integrated ecosystems simplify engineering and provide stronger diagnostics and support.

Can drives from different manufacturers be mixed in one machine?

Yes, but this may increase system complexity and troubleshooting difficulty.