Mitsubishi PLCs in Roll Forming Machines — FX, iQ-F & iQ-R Series

Introduction — Mitsubishi PLCs in Roll Forming Automation

Mitsubishi Electric PLC systems are widely used in industrial automation across Asia and many global manufacturing markets. Many roll forming machines built in Japan, China, Korea, and Southeast Asia use Mitsubishi PLCs because of their reliability, compact design, and strong motion control capabilities.

Mitsubishi PLCs are commonly used to control:

• roll forming line drives
• encoder-based length measurement
• hydraulic shear systems
• servo feed punching units
• flying shear systems
• production monitoring and alarms

Modern Mitsubishi PLCs are programmed using GX Works engineering software, which provides tools for PLC programming, diagnostics, and system configuration.

The most common Mitsubishi PLC families used in roll forming machines include:

• FX Series
• iQ-F Series
• iQ-R Series

Each system is designed for different machine sizes and automation complexity.

Mitsubishi PLC Architecture

A Mitsubishi PLC control system typically includes several integrated components that manage machine automation.

Typical system components include:

• PLC CPU processor
• digital input modules
• digital output modules
• analog I/O modules
• communication modules
• motion control modules
• HMI operator interface

The PLC reads signals from sensors and switches and sends commands to actuators such as motors, valves, and hydraulic systems.

This process repeats continuously during machine operation.

Mitsubishi FX Series PLC

Overview of the FX Series

The Mitsubishi FX series is one of the most widely used PLC families for small to medium automation systems.

These PLCs are commonly found in:

• basic roll forming machines
• stop-to-cut shear systems
• simple punching lines
• smaller production machines

The FX series is known for its compact design and reliability.

Features of FX PLC Systems

Key features include:

• compact integrated design
• high reliability
• simple expansion capability
• integrated communication options
• cost-effective automation platform

These characteristics make FX PLCs suitable for many standard roll forming applications.

Typical Roll Forming Applications

FX PLC systems are commonly used to control:

• machine start and stop logic
• encoder-based length measurement
• hydraulic shear control
• VFD drive commands
• simple alarm systems

For machines with moderate automation complexity, FX PLCs provide reliable performance.

Mitsubishi iQ-F PLC Series

Overview of iQ-F

The iQ-F series is the modern successor to the FX series and provides enhanced processing performance and connectivity.

It is commonly used in:

• modern roll forming machines
• machines requiring advanced communication networks
• systems requiring higher processing speed

The iQ-F PLC integrates several advanced features while maintaining a compact design.

Features of iQ-F Systems

Key features include:

• faster processing speeds
• integrated Ethernet communication
• improved memory capacity
• advanced motion control capabilities

These features make iQ-F PLCs suitable for more demanding roll forming applications.

Applications in Roll Forming Machines

Typical applications include:

• servo feed punching systems
• advanced recipe management
• improved machine diagnostics
• communication with production monitoring systems

These systems provide better performance compared with earlier FX models.

Mitsubishi iQ-R PLC Series

Overview of iQ-R

The iQ-R series is Mitsubishi’s high-performance automation platform designed for complex industrial systems.

These PLCs are typically used in:

• high-speed roll forming lines
• flying shear synchronization systems
• multi-axis servo control systems
• fully automated production lines

The iQ-R platform offers significantly greater processing power and system scalability.

Features of iQ-R PLC Systems

Key capabilities include:

• high-speed processors
• advanced motion control modules
• integrated safety control
• large system expansion capability
• advanced networking options

These features make iQ-R PLCs suitable for large industrial automation systems.

Mitsubishi Motion Control for Roll Forming

Many roll forming machines require motion control for precise synchronization.

Typical motion control applications include:

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

Mitsubishi PLC systems integrate with Mitsubishi servo drives to provide precise positioning and speed control.

Motion control modules allow accurate synchronization between machine components.

Industrial Networking with Mitsubishi PLCs

Mitsubishi PLC systems support several industrial communication protocols.

Common networks include:

• Ethernet/IP
• Modbus
• CC-Link
• CC-Link IE Field Network

These networks allow the PLC to communicate with drives, sensors, and other automation devices.

Reliable networking ensures stable machine operation.

PLC Programming with GX Works

Mitsubishi PLCs are programmed using GX Works software.

GX Works provides tools for:

• ladder logic programming
• system diagnostics
• device configuration
• network setup

Engineers can monitor machine signals in real time and troubleshoot automation issues.

Diagnostics and Troubleshooting

Mitsubishi PLC systems provide diagnostic features that allow technicians to identify machine faults quickly.

Diagnostics may include:

• input and output signal monitoring
• communication status indicators
• drive fault information
• alarm history logs

These tools help reduce machine downtime and simplify troubleshooting.

Commissioning Mitsubishi PLC Systems

Commissioning involves configuring the PLC and verifying system operation.

Typical commissioning steps include:

1. verifying input signals
2. testing output devices
3. configuring communication networks
4. calibrating encoder measurements
5. testing machine motion

Production testing should begin at low speed to ensure safe operation.

Preventative Maintenance for Mitsubishi PLC Systems

Routine maintenance improves system reliability.

Recommended maintenance practices include:

Monthly inspections:

• check cabinet ventilation
• inspect communication cables

Quarterly inspections:

• review PLC diagnostic logs
• verify drive communication

Annual maintenance:

• back up PLC programs
• inspect wiring connections

Regular inspections help prevent unexpected system failures.

Benefits of Mitsubishi PLC Systems in Roll Forming

Mitsubishi PLCs provide several advantages for roll forming automation.

These include:

• reliable industrial hardware
• compact system design
• strong motion control integration
• flexible communication options

These features make Mitsubishi PLC systems widely used in roll forming machines across global markets.

FAQ — Mitsubishi PLCs in Roll Forming Machines

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

Common Mitsubishi PLC platforms include the FX series for smaller machines, the iQ-F series for modern mid-range systems, and the iQ-R series for large automation systems.

What software is used to program Mitsubishi PLCs?

Mitsubishi PLCs are programmed using GX Works engineering software.

Can Mitsubishi PLCs control servo systems in roll forming machines?

Yes. Mitsubishi PLCs integrate with Mitsubishi servo drives to provide precise motion control for flying shear systems and servo feed punching units.

What communication networks are supported by Mitsubishi PLCs?

Mitsubishi PLCs support networks such as Ethernet/IP, Modbus, CC-Link, and CC-Link IE Field Network.

Are Mitsubishi PLCs suitable for high-speed roll forming lines?

Yes. The iQ-R series provides high processing power and advanced motion control capabilities for complex roll forming automation.

How are Mitsubishi PLC faults diagnosed?

GX Works software allows engineers to monitor system signals, communication networks, and device status in real time.