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國內(nèi)的包裝生產(chǎn)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(chǎn)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(chǎn)線中，使生產(chǎn)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(guān)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(chǎn)線的末端產(chǎn)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(shè)計的碼垛線為雙線輸送，碼垛能力能達到 60 箱 / 分，主要應(yīng)用在食品行業(yè)。該碼垛線通過 PLC 控制將兩條生產(chǎn)線上輸送過的產(chǎn)品分別輸送到對應(yīng)的堆疊區(qū)，且通過觸摸屏可設(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(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。碼垛線裝備實物圖片如圖 1 所示。
貨物由入口輸送帶1進入，經(jīng)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(zhuǎn)向 ( 如需轉(zhuǎn)向則轉(zhuǎn)向氣缸動作 ) 并計數(shù)，PLC 進行判斷產(chǎn)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(chǎn)品;當(dāng)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(yīng)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(zhuǎn)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(qū)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(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
　　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(shè)計時，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)計分為主程序和子程序兩部分，主程序中 AB 兩線運行各自調(diào)用相應(yīng)子程序。子程序主要有：開機初始化程序、各設(shè)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(fù)位及數(shù)量清零等子程序組成，如圖 3 所示。

ALLEN BRADLEY 8200014735 USPP 8200014735

MODICON AS-J212-001 USPP ASJ212001

OMRON CV500-BSC11 NSFP CV500BSC11

YAMATAKE 82114930-002 USPP 82114930002

RELIANCE ELECTRIC 0-51839-11 NSPP 05183911

Siemens 6ES5-453-4UA12/6ES5453-4UA12 OUTPUT MODULE NIB

SIEMENS 6ES5-380-7AA11 USPP 6ES53807AA11

SIEMENS Digital Input Module 6ES5 436-4UA12 NIB OPENED TO TAKE PICTURES

Siemens 6ES5 998-0UP21 NSPP 6ES59980UP21

SIEMENS 6ES5470-4UA12 6ES54704UA12 NIB

SIEMENS MP277-10 6AV6 643-0CD01-1AX1 Touchscreen Glass

RELIANCE ELECTRIC 0-57416-K NSPP 057416K

Texas Instruments 500-5052

Square D NEHB442ASP-N Power Interface Module Make An Offer

Unisphere Juniper ERX1400 SRP-10-ECC 10-Gbps SRP module Make Offer

Siemens capacitors 0.68uF 100V 500 pcs NIB

Modicon AS-W904-006

Schneider Modicon 5 Slot Secondary Subrack DTA 201/AS-HDTA-201 WARRANTY

Schneider Modicon P890 I/O PROCESSOR AS-P890-000

Schneider Modicon AS-BDAP-258 NSFP ASBDAP258

Schneider Modicon AS-BADU-205

Schneider Modicon /GOULD/AS-884A-101 PROCESSOR 2K W/REMOTE I/O

Schneider Modicon COMM. PROCESSOR MODULE AS-C921-000

Schneider Modicon TSXP575634M

SCHNEIDER TSX MICRO TSXDEZ08A4 DISCRETE INPUT MODULE

Ready bundle for WS-X6708-10G-3C 8 Cisco X2-10GB-ER

SIEMENS 6ES5-470-4UA12/6ES5470-4UA12 OUTPUT MODULE NIB

SIEMENS SINUMERIK OP010 6FC5 203-0AF00-0AA0 MembraKeypad

Mitsubishi MELSEC A1S-D51S A1SD51S Communication Module PLC Programmable

SIEMENS Simodrive 6SN1118-0AA11-0AA1 Module

SIEMENS Sinumerik Hand Wheel 6FC9320-5DC00

SIEMENS 6FC5210-0DF21-2AA0 DRIVE

AllenBradley1746-IO12SeriesBInputOutputModuleSLC500Bulletin1746

ALLEN BRADLEY SLC 500 4-CHANNEL ANALOG INPUT / OUTPUT MODULE 1746 F104V

ABB ROBOT SERVO 3HAC 3579-1/04

A06B-0143-B088#7076 FANUC SERVO MOTORS REMANUFACTURED

0020-39001 - VALVE, Throttle PLUNGER

MODICON PC-BALU-821 NSFP PCBALU821

ALLEN BRADLEY 150-B360NBD USPP 150B360NBD

ALLEN BRADLEY 1326AB-C2C-21 USPP 1326ABC2C21

GENERAL ELECTRIC 269-120N-125VDC USPP 269120N125VDC

SQUARE D HDMPM21012186 NSFP HDMPM21012186

SIEMENS 6SC6-120-0FE01 USPP 6SC61200FE01

ASEA BROWN BOVERI 57340001-K/2 USPP 57340001K2

Siemens 6ES5 943-7UB11 -- 6ES59437UB11

Siemens SIMATIC S5 6ES5 456 7LA11

SIEMENS 6ES5-700-2LA12 NSPP 6ES57002LA12

Siemens 6ES5 456-4UA12SERIES DIGITAL OUTPUT MODULE 16POINT 55025

SIEMENS 64kB MMC 6ES7953-8LF20-0AA0

Siemens HMI PP7 6AV3688-3AA03-0AX0 Operator panel

SANS DIGITAL MR4UT MobileRaid 4-bay hardware RAID

Square D FAL34025

SIEMENS HTRI-D INTEL INTERFACE DUAL MODULE

SERIES E CAT REV K01 F/W REV D.1

Siemens 6SE7018-0EA84-1HF3

Siemens TP7 6AV3607-1NH01-0AX0 Touch Glasss

Schneider Modicon DEP210/AS-BDEP-210 INPUT MODULE NIB

Schneider Modicon ASB885002 GOULD MODULE AS-B885-002

Schneider Modicon AS-B837-016 USPP ASB837016

Schneider Modicon SEALED AS-B829-116 MODULE

Schneider Modicon B804 AS-B804-016 115V 16PT INPUT MOD ASSEMBLY

Schneider Modicon AS-H819-209 Housing Assembly 800 rack plc 19"

Schneider PLC Analog Output Module 170AAO12000

Siemens 6ES5430-4UA12 Simatic Input Module 20280

Roland Fantom XR SRX-05 upgraded 128-Voice Synthesizer / Sampler Module-MIDI 2

SIEMENS CONTROL MONITOR M IPC3510A300MGT TOUCH SCREEN

SIEMENS SINUMERIK 840DE 6FC5356-0BB14-0AA0 NCU 561.4

RELIANCE ELECTRIC NETWORK COMMUNICATION PLC MODULE 57404-1 57-404-1 57404-1F

SIEMENS CONTROLLER CARD 6SN1118-0AD11-0AA0 ~

SIEMENS SIMODRIVE SERVO DRIVE 6SN1145-1AA01-0AA2

SIEMENS 6FC5110-0CB01-0AA0 6FC51140CB010AA0 version E

ALLENBRADLEY2711P-T9C1OPERATORINTERFACEPANELVIEW900SERIESCREVC

Allen Bradley Versaview 1500P 6181P-15TPXPHSS Rev A Ser C For Windows XP AB/COA

ABB FI803F 3BDH000032R1 good in condition for industry use

Advanced Energy ATX-600 Impedance Matching Network -

(M3) 1 BAYSIDE ( Parker) RA142-010-LB GEAR HEAD MOTOR M3

MARPOSS 3014332600 USPP 3014332600

ALLEN BRADLEY 1334-FOB-T4 USPP 1334FOBT4

GE FANUC IC3600LSRB1 NSPP IC3600LSRB1

FANUC A06B-6058-H221 USPP A06B6058H221

SIEMENS 1LA0364-2SP22 NSFP 1LA03642SP22

RELIANCE ELECTRIC 0-60002-5A USPP 0600025A

SIEMENS 6DS1302-8AB USPP 6DS13028AB

Siemens 6ES5 466-4UA11

Siemens 6ES5-944-7UA12 USPP 6ES59447UA12

SIEMENS 6ES5-435-7LA11 NSFP 6ES54357LA11

Siemens 6ES5 700-8MA11 Bus Module w/Warranty

Siemens S5 6ES5 927-3SA11 6ES59273SA11

Siemens C79451-A3276-A1

SIEMENS 6ES5-305-7LB11 NSPP 6ES53057LB11

Square D 8020 SCP-321

NUM Interface Module 32 E _ 263202926 _ 2632O2926

WS-C3750G-48TS-S CISCO 3750G-48TS SWICTH W/1 YR -WSC3750G48TSS

Siemens 6ES7231-7PD21-0XB0 6ES72317PD210XB0

SIEMENS SIMATIC PANEL PC 870 PC870 6AV7743-2AC00-0AA0 Membrane Keypad

Reliance 612405-9R

Schneider Modicon BKF-201AS-BBKF-201 BKF201 Free Ship

Schneider Modicon AS-B374-001 ASB374001 Analog Output FS

Schneider Modicon AS-T484-002 USPP AST484002

Schneider Modicon AS-BDAP-210 DISCRETE OUTPUT MODULE

Schneider Modicon AS-B824-000 I/O Module

MODICON AS-B355-001 OUTPUT MODULE OLD STOCK FREE SAME DAY SHIPPING USA

Siemens Input Module 6ES5 436 4UB12 SURPLUS

SIEMENS 505-9201 MICRO-REMOTE I/O MODULE 5059201

SIEMENS OUTPUT MODULE 2AMP 24VDC 1P 6ES7 132-4BB30-0AA0

SIEMENS Simodrive Sinumerik 6RB2100-0NA21 includes 6RB2100-0SA21

TELLABS 5323B PORT SERIAL MODULE 825310 Communications

SIEMENS 6SN1118-0DM21-0AA0 6SN11180DM210AA0 NIB

SIEMENS Simodrive / Sinumerik E52930-A3210-C5-B1 Board.

SIEMENS 6FC5357-0BB12-0AE0 SINUMERIK 840D 6FC5247-0AA00-0AA3

ADVANTECH PCM-4823 Single Board Computer

Allen-Bradley 1746-OW16 Output Module

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 84812

ADEPT TECH 10330-00500 NSPP 1033000500

(#3461) SEW Eurodrive MoviDrive MDS60A0300-503-4-00 NIB

HUNKAR LABS 315-0 USPP 3150

TB WOODS WFC-4050-0CHT USPP WFC40500CHT

DIGITAL COMPUTER 5016017-01-D1-P3 USPP 501601701D1P3

CROUSE HINDS WSR6351 NSPP WSR6351

PACIFIC SCIENTIFIC SC752A001-02 USPP SC752A00102

MODICON AS-506P-002 NSFP AS506P002

HERION 59-989-15 USPP 5998915

Siemens 6ES5 308-3UB11 NIB Free Ship

Siemens 6ES5-525-3UA11 USPP 6ES55253UA11

SIEMENS 6ES5-372-0AA61/6ES5372-0AA61 MEMORY SUBMODULE NIB

Siemens 6ES5 232-1AA11 S5 PLC CARD CIRCUIT BOARD MODULE EMA-W88 56781

Siemens 6ES5-452-8MR11Output Module 4POINT 24VDC

SIEMENS 6GK7-242-2AX00-0XA0 6GK7242-2AX00-0XA0 FreeShip

Siemens TP177B 6AV6642-0BA01-1AX1 Touchscreen Glass

Siemens 6ES5725-2AC01

Landis Gyr Powers System 600 536-050 LOT Power Modules Trunk Interface HVAC

YASKAWA ELECTRIC JAMSC-B1051B USPP JAMSCB1051B

SIEMENS 6ES7 222-1HF32-0XA0 6ES7222-1HF32-0XA0 FreeShip

Siemens OP37 6AV3 637-1LL00-0AX1 Membrane Keypad

Red Lion PRA1-3021

Schneider Modicon AS-B810-008 Isolated Output Module 115 VAC ASB810008

Schneider Modicon AS-884A-200 USPP AS884A200

Schneider Modicon AS-P120-000 USPP ASP120000

Schneider Modicon AS-B239

Schneider Modicon AS-516P-008 CNC Memory Board AIPR/UVG

Modicon XBT FC044610 Telemecanique Magelis 24VDC 35W

Siemens Simatic S7-200 PLC 6ES7 221-1BF22-0XA0 DC Input Module

TELEMECANIQUE TSX-ASZ-200 TSXASZ200

Siemens Simatic Relay Output Module U-05T

Siemens 9610 9610DC-1155-GZZA Power Meter Display ION Ethernet Access NNB

SIEMENS Sinumerik FPCI/ISA 6FC5247-0AA02-1AA0 6FC5 247

SIEMENS 6SN1118-1NH00-0AA2 6SN11181NH000AA2

SIEMENS SIMODRIVE 6SN1123-1AA02-0FA0

SIEMENS I/O MODULE 6FC3984-3RA 6FC39843RA 64E/32AUSGAEN

Advantech PCM-3810 A2 PC/104

Allen-Bradley 2711-K5A8 PanelView 550 Operator Interface Panel

ABB 5SDD0760D0001 3BHL001862P0001 Thyristor for ACS1000 AC Drive

Acrison 305-0096 Gearbox BDF1.5 OUT THD

AAT-SOT23-5-AAT1106 2-CHANNEL STEP-UP PWM IC Controller

85179 , Dayton 1LNF4 AC Adj Frequency Drive, 20 HP, 3 PH, 460V

SIEMENS 6SE3-121-7DG40 NSFP 6SE31217DG40

ATLAS COPCO PF2102-S7-115R USPP PF2102S7115R

ASEA BROWN BOVERI DSQC 314B USPP DSQC314B

MITSUBISHI Q173-CPU-N USPP Q173CPUN

INDRAMAT MAC-132A-1-JD-4-C/230-R-0/DIS20LX/S001 USPP MAC132A1JD4C230R

ASEA BROWN BOVERI 3HAB2220-1 USPP 3HAB22201

TEXAS INSTRUMENTS PLC 500-2102 NSPP 5002102

Siemens 6ES5-441-4UA14 USPP 6ES54414UA14

SIEMENS 6ES5 482-8MA13 DIGITAL I/O MODULE

SIEMENS S5 6ES5 308-3UA12 Serial Interface 6ES53UA12

Siemens S5 6ES5 470-7LB12 Analog Output 6ES5470-7LB12

SIEMENS 6ES7 621-6BD01-0AE3 SIMATIC S7 C7-621 ASI Worldwide

Siemens S5 6ES5 928-3UB21 S5 6ES5928-3UB21 CPU CPU928B

PPT Machine Vision Impact C40 Processor Cables I/O Bd

Honeywell Ademco 4100SM Serial Interface Module

VW Volkswagen Jetta Golf GTI Bluetooth Interface Communication Module 1K8035730D

SIEMENS 6DS1212-8AB

Siemens LOGO! 230RC 6ED1 052-1FB00-0BA5 6ED10521FB000BA5

Omron 3G2A5-OC224

Schneider Modicon AS-P120-000 PLC

Schneider Modicon LEVEL-3 16K 3CARD CHASSIS 584 AS-584A-320

Schneider Modicon AS-H819-100 USPP ASH819100

Schneider Modicon Gould/ AS-984A-008

Schneider Modicon AS-BDAP-218 FACTORY SEALED Discreet Output Relay ASBDAP218

Schneider Modicon Reed Relay Output Module AS-B840-108 - Repaired

Telemecanique GV2ME10C / 4-6.3A Motor Circuit Breaker

Schneider TELEMECANIQUE MODICON TSXRKZ02 Exsion Rack

Siemens6DD1642-0BC0Analog Output Module SDYND EA12

Siemens 6AV6 545-0BA15-2AX0 6AV65450BA152AX0 Panel

SIEMENS Sinumerik 6FC5111-0CA01-0AA0 DMP 16 Output E-Modul Compact -

GE FANUC ENHANCED COMMUNICATION MODULE IC693CMM302C

SIEMENS SIMODRIVE 6SN1145-1BA01-0DA1SINUMETIK 840D NCU 6FC52476SN11236FC5357

SIEMENS SINUMERIK 3/800 6FC3988-7AH20 TESTED WARRANTY

SIEMENS IBM 6400 Model 015 Printer Ribbons - IBM 6400 Model 15

ALLEN-BRADLEY DATALINER OPERATOR INTERFACE CAT2706-D21J8

A-B NIPPONDENSO 8500-A3D-L1B AC Servo Motor [PZ4]

AC Motor Invertor - 30 HP - 480 Volt - Three Phase Input

A06B-0583-B072#7008 FANUC SERVO MOTORS REMANUFACTURED

750' Notre Dame 1/0 1/0 1/0 2 Aluminum URD Direct Burial URD XLP USE 600V

RELIANCE ELECTRIC GV3000E-AC008-AA-DBU NSFP GV3000EAC008AADB

ALLEN BRADLEY 5250-LP1 USPP 5250LP1

ALLEN BRADLEY 2094-BC07-M05S USPP 2094BC07M05S

INDRAMAT KDS1.1-150-300-W1 USPP KDS11150300W1

YASKAWA ELECTRIC CACR-TM333Z1SPY8 NSFP CACRTM333Z1SPY8

WESTINGHOUSE 210P085H01-1 USPP 210P085H011

HYDE PARK SP106 USPP SP106

Siemens 6ES5-244-3AA22 USPP 6ES52443AA22

SIEMENS 6ES5 376-1AA31 -- 6ES53761AA31

SIEMENS Interface Module 6ES5 752-0AA43 WITH PAPERWORK

Siemens Analog Input Module 6ES5 460-7LA12

Siemens 6ES7 131-0BL00-0XB0 6ES7131-0BL00-0XB0 ET200B

SIEMENS MP370 12.1" MP370-12 6ES7542-0DA10-0AX0 Touch Screen Display Glass

Reliance Automate 30 45C305A 45C305 Processor

Texas Instruments 505-4508

STATIC CONTROLS 920-M-2-V 4.3 INTERFACE DISPLAY MODULE

UBR7246VXR CISCO UBR 7246 4MC 2PA SLOTS 1YR - ASK 4 QTY

Siemens Control Board C98043-A1304-L Simodrive

Modicon AS-WBXT-201

Schneider Modicon NIBAutomation Output Module DAP 210/AS-BDAP-210

Schneider Modicon AEG/GOULD/MODICON/ AS-E381-902 EXECUTIVE CARTRIDGE XLNT

Schneider Modicon AS-BDEP-112 NSFP ASBDEP112

Schneider Modicon ASBDAP216 Compact Out Module AS-BDAP-216

Schneider Modicon -AS-500P-000

Schneider Modicon DAP 218 DAP218 Output Module AS B075-000 94V

Schneider Proximity Sensor XS530B1DAL2 NIB DC12-48V

SCHNEIDER MODICON TSX QUANTUM 115V AC INPUT MODULE 140 DAI 540 00

QX41 Mitsubishi PLC 32 Point DC Input

SIEMENS 6ES5456-4UA12 Digital Output Module NIB-FS

SIEMENS Sinumerik 802S 802C 802 5.7 inch LCD screen display