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國內的包裝生產線在發(fā)展初期一般只能完成物料包裝，后續(xù)的搬運工作則由搬運工人來完成。隨著產量的日益擴大，傳統(tǒng)的人工搬運方式顯然無法滿足需求，碼垛機械的出現(xiàn)為這一問題提供了有效的解決方案。
　　碼垛機可以集成在生產線中，使生產現(xiàn)場變得智能化，可以實現(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，減輕個人體力勞動，減員增效起到了關鍵作用。目前主流的控制系統(tǒng)采用 PLC+ 機械手的方式，對整條生產線的末端產品進行整理、堆疊、整垛輸出等。
　　目前市場上主流的碼垛線為單線輸送系統(tǒng)，碼垛能力在 30~40 箱 / 分，具體的碼垛能力視貨物而異。本項目中設計的碼垛線為雙線輸送，碼垛能力能達到 60 箱 / 分，主要應用在食品行業(yè)。該碼垛線通過 PLC 控制將兩條生產線上輸送過的產品分別輸送到對應的堆疊區(qū)，且通過觸摸屏可設定不同的層數(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
　　碼垛線分為 A、B 兩線，每條線均由以下部分組成：入口輸送帶 1、入口輸送帶 2、入口輸送帶 3、分離電機、轉向電磁閥、轉向滾筒、堆疊輸送帶，出口輸送帶等;A、 B 兩線共用棧板供應系統(tǒng)和左右棧板輸送帶等設備。碼垛線裝備實物圖片如圖 1 所示。
貨物由入口輸送帶1進入，經過三個入口緩存輸送帶，輸送到分離電機處;分離電機分離后根據(jù)需要確認是否轉向 ( 如需轉向則轉向氣缸動作 ) 并計數(shù)，PLC 進行判斷產品是否已完成一列。達到一列后控制推桿動作，將貨物整平。此時，PLC 發(fā)出 DO 信號給 ABB 機械手 (ABB 機械手與 PLC 通過硬接線連接 )，機械手動作抓取已完成碼垛的一列產品;當完成一垛后，堆疊電機動作，將已完成堆垛的貨物整垛輸出;然后棧板供應啟動，為缺少棧板的堆疊區(qū)提供棧板，依次循環(huán)實現(xiàn)持續(xù)碼垛。其工藝流程如圖 2 所示。
　3 自動化平臺選型
　　鑒于該碼垛機 I/O 點數(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)選型時采用西門子 S7-200 SMART PLC 作為主控制器，因為 S7-200 SMART 具備 60I/O 的大點數(shù) CPU 以及高密度擴展模塊，并且模塊體積緊湊，能夠有效滿足以上需求。碼垛線上的轉向氣缸、滾筒等動作頻繁，高達 20~30 次 / 分，故采用晶體管輸出類型，外接中間繼電器驅動大負載。在HMI選型上，單線系統(tǒng)選用7寸屏即能滿足要求，但對于雙線控制系統(tǒng)，需要顯示的信息更多，最終選用 10 寸屏。同時，屏上集成的以太網(wǎng)接口與 S7-200 SMART 無縫連接，編程調試、設備通訊都很方便。電控系統(tǒng)配置如附表所示。
4.1 結構化模塊設計
　　由于碼垛線控制點數(shù)較多，程序較大，而且各部分功能較為分明，所以在軟件設計時，采用結構化編程的理念可使程序結構更加分明。程序設計分為主程序和子程序兩部分，主程序中 AB 兩線運行各自調用相應子程序。子程序主要有：開機初始化程序、各設備手動控制程序、入口計數(shù)子程序、整列推桿初始化子程序、自動運行子程序、堆疊方式處理子程序、故障報警子程序、系統(tǒng)復位及數(shù)量清零等子程序組成，如圖 3 所示。

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