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國(guó)內(nèi)的包裝生產(chǎn)線(xiàn)在發(fā)展初期一般只能完成物料包裝，后續(xù)的搬運(yùn)工作則由搬運(yùn)工人來(lái)完成。隨著產(chǎn)量的日益擴(kuò)大，傳統(tǒng)的人工搬運(yùn)方式顯然無(wú)法滿(mǎn)足需求，碼垛機(jī)械的出現(xiàn)為這一問(wèn)題提供了有效的解決方案。
　　碼垛機(jī)可以集成在生產(chǎn)線(xiàn)中，使生產(chǎn)現(xiàn)場(chǎng)變得智能化，可以實(shí)現(xiàn)飲料、食品、日化等行業(yè)各種作業(yè)的碼垛物流，為企業(yè)改善工作條件，減輕個(gè)人體力勞動(dòng)，減員增效起到了關(guān)鍵作用。目前主流的控制系統(tǒng)采用 PLC+ 機(jī)械手的方式，對(duì)整條生產(chǎn)線(xiàn)的末端產(chǎn)品進(jìn)行整理、堆疊、整垛輸出等。
　　目前市場(chǎng)上主流的碼垛線(xiàn)為單線(xiàn)輸送系統(tǒng)，碼垛能力在 30~40 箱 / 分，具體的碼垛能力視貨物而異。本項(xiàng)目中設(shè)計(jì)的碼垛線(xiàn)為雙線(xiàn)輸送，碼垛能力能達(dá)到 60 箱 / 分，主要應(yīng)用在食品行業(yè)。該碼垛線(xiàn)通過(guò) PLC 控制將兩條生產(chǎn)線(xiàn)上輸送過(guò)的產(chǎn)品分別輸送到對(duì)應(yīng)的堆疊區(qū)，且通過(guò)觸摸屏可設(shè)定不同的層數(shù)采用不同的堆疊方式，如第 1 層按方式 1 堆疊，第 2 層按方式 2 堆疊，碼垛方式靈活。
　　2 工藝要求
　　碼垛線(xiàn)分為 A、B 兩線(xiàn)，每條線(xiàn)均由以下部分組成：入口輸送帶 1、入口輸送帶 2、入口輸送帶 3、分離電機(jī)、轉(zhuǎn)向電磁閥、轉(zhuǎn)向滾筒、堆疊輸送帶，出口輸送帶等;A、 B 兩線(xiàn)共用棧板供應(yīng)系統(tǒng)和左右棧板輸送帶等設(shè)備。碼垛線(xiàn)裝備實(shí)物圖片如圖 1 所示。
貨物由入口輸送帶1進(jìn)入，經(jīng)過(guò)三個(gè)入口緩存輸送帶，輸送到分離電機(jī)處;分離電機(jī)分離后根據(jù)需要確認(rèn)是否轉(zhuǎn)向 ( 如需轉(zhuǎn)向則轉(zhuǎn)向氣缸動(dòng)作 ) 并計(jì)數(shù)，PLC 進(jìn)行判斷產(chǎn)品是否已完成一列。達(dá)到一列后控制推桿動(dòng)作，將貨物整平。此時(shí)，PLC 發(fā)出 DO 信號(hào)給 ABB 機(jī)械手 (ABB 機(jī)械手與 PLC 通過(guò)硬接線(xiàn)連接 )，機(jī)械手動(dòng)作抓取已完成碼垛的一列產(chǎn)品;當(dāng)完成一垛后，堆疊電機(jī)動(dòng)作，將已完成堆垛的貨物整垛輸出;然后棧板供應(yīng)啟動(dòng)，為缺少棧板的堆疊區(qū)提供棧板，依次循環(huán)實(shí)現(xiàn)持續(xù)碼垛。其工藝流程如圖 2 所示。
　3 自動(dòng)化平臺(tái)選型
　　鑒于該碼垛機(jī) I/O 點(diǎn)數(shù)較多 (DI 為 75，DO 為 40)，以及電控柜空間限制的需求，在系統(tǒng)選型時(shí)采用西門(mén)子 S7-200 SMART PLC 作為主控制器，因?yàn)?S7-200 SMART 具備 60I/O 的大點(diǎn)數(shù) CPU 以及高密度擴(kuò)展模塊，并且模塊體積緊湊，能夠有效滿(mǎn)足以上需求。碼垛線(xiàn)上的轉(zhuǎn)向氣缸、滾筒等動(dòng)作頻繁，高達(dá) 20~30 次 / 分，故采用晶體管輸出類(lèi)型，外接中間繼電器驅(qū)動(dòng)大負(fù)載。在HMI選型上，單線(xiàn)系統(tǒng)選用7寸屏即能滿(mǎn)足要求，但對(duì)于雙線(xiàn)控制系統(tǒng)，需要顯示的信息更多，最終選用 10 寸屏。同時(shí)，屏上集成的以太網(wǎng)接口與 S7-200 SMART 無(wú)縫連接，編程調(diào)試、設(shè)備通訊都很方便。電控系統(tǒng)配置如附表所示。
4.1 結(jié)構(gòu)化模塊設(shè)計(jì)
　　由于碼垛線(xiàn)控制點(diǎn)數(shù)較多，程序較大，而且各部分功能較為分明，所以在軟件設(shè)計(jì)時(shí)，采用結(jié)構(gòu)化編程的理念可使程序結(jié)構(gòu)更加分明。程序設(shè)計(jì)分為主程序和子程序兩部分，主程序中 AB 兩線(xiàn)運(yùn)行各自調(diào)用相應(yīng)子程序。子程序主要有：開(kāi)機(jī)初始化程序、各設(shè)備手動(dòng)控制程序、入口計(jì)數(shù)子程序、整列推桿初始化子程序、自動(dòng)運(yùn)行子程序、堆疊方式處理子程序、故障報(bào)警子程序、系統(tǒng)復(fù)位及數(shù)量清零等子程序組成，如圖 3 所示。

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