In order to solve the existing problems of inefficiency, instability, inaccuracy and low degree of automation, the roll position automatic adjustment system is designed for the one-time forming of cold-formed steel unit. The automatic control technology, sensor technology, communication technology and human–machine interface (HMI) configuration technology are applied to this system and the high-performance PLC controller is used as control core. Triple-phase asynchronous motors are controlled by PLC (S7-1500) to drive the gear connected with reducer and coupling so as to drive the rolls connected with the upper and lower horizontal axes to move. The osiswitch is used to calibrate zero position and the closed-loop control system is constructed by analyzing and feedbacking the signal of the sensor. In this way the system can improve the roll position adjustment accuracy. The practical applications show that the whole system is simple, stable and efficient and the maximum detection error of roller displacement is only [Formula: see text]2[Formula: see text]mm. The system can automatically call the corresponding roll position data according to the specification of the steel pipe. The system not only improves the adjustment speed and accuracy, but also avoids the waste of manpower so that the enterprise production efficiency can be greatly improved. Meanwhile, in order to carry out efficient management of the unit, the unit’s health management system was used to analyze and monitor the status of the unit in real-time.