Delta PLCs & HMIs for Roll Forming Machines — Where They Fit and Their Limits

Introduction — Why Delta PLCs Are Common in Budget Roll Forming Machines

Delta automation systems are widely used in cost-sensitive roll forming machines, especially in markets where affordability and simplicity are important factors.

Manufacturers building entry-level or mid-range roll forming lines often choose Delta controllers because they offer a balance between functionality and cost.

Delta PLCs are commonly found in machines built for:

• roofing panel production
• trim and flashing lines
• basic purlin machines
• small construction profile machines

Delta automation hardware is frequently used in machines exported from Asia and installed in developing markets.

Typical Delta automation systems include:

• Delta PLC controllers
• Delta HMI operator panels
• Delta VFD motor drives
• Delta servo systems

These components allow manufacturers to build complete automation systems at relatively low cost.

However, Delta PLC platforms also have certain limitations when compared with higher-end automation systems.

Understanding where Delta systems perform well — and where they reach their limits — is important when designing or upgrading roll forming machines.

Overview of Delta PLC Architecture

Delta PLC systems are designed to provide reliable industrial control for machines with moderate automation requirements.

A typical Delta automation system includes:

• PLC controller
• digital input modules
• digital output modules
• analog input/output modules
• HMI operator interface
• communication interfaces

The PLC receives signals from sensors and sends commands to machine devices such as motors, valves, and hydraulic systems.

Control logic is executed continuously during machine operation.

Delta PLC Series Used in Roll Forming Machines

Several Delta PLC models are commonly used in roll forming equipment.

Typical platforms include:

• DVP Series PLCs
• AS Series PLCs

These systems provide different levels of processing capability and system expansion.

Delta DVP Series PLC

Overview

The Delta DVP Series PLC is one of the most widely used Delta control platforms in industrial machines.

It is commonly used in smaller roll forming machines because it provides reliable control with relatively simple programming.

Typical Applications in Roll Forming

DVP PLCs are often used for:

• basic machine start/stop logic
• encoder length measurement
• hydraulic stop-to-cut shear control
• simple punching operations
• alarm monitoring

These PLCs provide sufficient capability for many standard roll forming applications.

Advantages of the DVP Series

The DVP platform offers several benefits.

These include:

• low cost
• simple programming environment
• reliable industrial operation
• compact hardware design

These advantages make the DVP series attractive for machines where advanced automation is not required.

Delta AS Series PLC

Overview

The AS Series PLC is a newer Delta platform designed for more advanced automation systems.

It offers greater processing power and expanded communication options compared with the DVP series.

Applications in Roll Forming Machines

AS series PLCs are used in more advanced machines such as:

• multi-profile roll forming lines
• machines requiring higher communication speeds
• systems integrating servo control

The increased processing capability allows the controller to manage more complex machine functions.

Delta HMI Operator Interfaces

Delta HMIs are commonly used alongside Delta PLC systems.

These operator interfaces provide graphical control of the machine.

Typical HMI functions include:

• machine start and stop commands
• alarm display
• recipe selection
• production counters

Delta HMIs are known for their affordability and simple configuration.

They are often used in machines where advanced visualization is not required.

Industrial Networking with Delta Systems

Delta PLCs support several industrial communication protocols.

Common networks include:

• Modbus RTU
• Modbus TCP
• Ethernet communication

These networks allow the PLC to communicate with devices such as:

• VFD motor drives
• servo drives
• remote I/O modules

However, Delta communication systems are generally simpler than those found in high-end automation platforms.

Motion Control Capabilities

Delta PLC systems can support basic motion control applications.

Typical motion functions include:

• servo feed positioning
• indexing motion
• simple synchronization

These capabilities are sufficient for many roll forming applications such as punching systems or positioning operations.

However, extremely complex motion control tasks may require more advanced automation platforms.

Where Delta PLC Systems Work Well

Delta automation platforms perform well in many roll forming applications.

They are particularly suitable for machines with:

• simple stop-to-cut shear systems
• moderate production speeds
• limited servo motion requirements
• basic operator interfaces

For these applications, Delta PLCs provide reliable control at a lower cost than many competing systems.

Limitations of Delta PLC Systems

Despite their advantages, Delta PLC systems also have limitations.

These may include:

• lower processing speed compared with high-end PLCs
• limited advanced motion control capability
• simpler networking options
• fewer diagnostic tools

These limitations may become noticeable in machines with complex automation requirements.

When to Consider Higher-End PLC Platforms

Some roll forming machines require more advanced control systems.

Examples include:

• high-speed flying shear systems
• multi-axis servo synchronization
• fully automated production lines
• integration with factory-wide automation networks

In these cases, manufacturers often use higher-end PLC platforms designed for advanced motion control and networking.

Commissioning Delta PLC Systems

Commissioning Delta-based roll forming machines involves verifying system configuration and machine operation.

Typical commissioning steps include:

1. verifying input and output signals
2. testing communication with drives
3. calibrating encoder length measurement
4. testing machine motion at low speed

These steps ensure the machine operates safely and reliably.

Preventative Maintenance for Delta PLC Systems

Routine maintenance helps maintain system reliability.

Recommended practices include:

Monthly inspections:

• check control cabinet ventilation
• inspect communication cables

Quarterly inspections:

• review PLC diagnostics
• verify encoder signals

Annual maintenance:

• back up PLC programs
• inspect wiring connections

Proper maintenance reduces the risk of unexpected automation failures.

Benefits of Delta Automation Systems in Roll Forming

Delta PLC and HMI systems offer several advantages.

These include:

• low system cost
• simple configuration
• reliable industrial hardware
• compact system architecture

These features make Delta systems attractive for many entry-level roll forming machines.

FAQ — Delta PLC Systems in Roll Forming Machines

Why are Delta PLCs used in roll forming machines?

Delta PLCs provide reliable automation control at a lower cost than many high-end PLC platforms.

What Delta PLC models are commonly used in roll forming machines?

The most common models include the DVP series for smaller machines and the AS series for more advanced automation systems.

Can Delta PLCs control servo systems?

Yes. Delta PLCs can control basic servo positioning systems used for punching or indexing applications.

Are Delta PLC systems suitable for high-speed roll forming lines?

Delta PLCs can handle moderate production speeds, but very high-speed lines may require more powerful automation platforms.

What communication protocols do Delta PLCs support?

Delta PLCs commonly support Modbus RTU, Modbus TCP, and Ethernet communication.

Why are Delta HMIs popular in roll forming machines?

Delta HMIs are affordable, easy to configure, and provide sufficient functionality for most operator interface requirements.