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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(yùn)工作則由搬運(yùn)工人來完成。隨著產(chǎn)量的日益擴(kuò)大，傳統(tǒng)的人工搬運(yùn)方式顯然無法滿足需求，碼垛機(jī)械的出現(xiàn)為這一問題提供了有效的解決方案。
　　碼垛機(jī)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(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(jī)械手的方式，對整條生產(chǎn)線的末端產(chǎn)品進(jìn)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(xiàng)目中設(shè)計的碼垛線為雙線輸送，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(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(shí)物圖片如圖 1 所示。
貨物由入口輸送帶1進(jìn)入，經(jīng)過三個入口緩存輸送帶，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)向氣缸動作 ) 并計數(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作，將貨物整平。此時，PLC 發(fā)出 DO 信號給 ABB 機(jī)械手 (ABB 機(jī)械手與 PLC 通過硬接線連接 )，機(jī)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(jī)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(shí)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(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)選型時采用西門子 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，能夠有效滿足以上需求。碼垛線上的轉(zhuǎn)向氣缸、滾筒等動作頻繁，高達(dá) 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(fù)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(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(yùn)行各自調(diào)用相應(yīng)子程序。子程序主要有：開機(jī)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(yùn)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 150-A500NBD USPP 150A500NBD

GE FANUC IC3600LSRB1 USPP IC3600LSRB1

ATLAS COPCO D312-DS9 USPP D312DS9

RELIANCE ELECTRIC 86466-75R NSFP 8646675R

GENERAL ELECTRIC THJV6DPK NSFP THJV6DPK

ASEA BROWN BOVERI 57310001-S USPP 57310001S

Siemens 6ES5 375-0LD31 6ES53750LD31

Siemens 6ES5-188-3UA12 PLC Rack 21 Slot

SIEMENS 6ES5 375-0LC31 6ES53750LC31

SIEMENS 6ES5-988-3NA11 USPP 6ES59883NA11

Siemens 6ES5 930-8MD11/6ES5930-8MD11 POWER SUPPLY XLNT

Siemens 6ES5 944-7UB11 in Sealed Box

Siemens Micromaster 430 6SE6430-2UD31-8DA0 18.5KW

RELIANCE ELECTRIC 61C-350 USPP 61C350

Texas Instruments 500-2151

Spirent Adtech AX/4000 401381 L3 Gigabit MM Interface

VIA Artigo A2000 Barebones Storage Server 1.5 GHz VIA C7-D Brand

Siemens C98043-A1604-L3-03 no packaging

Modicon AS-W510-002

Schneider Modicon Automation AS-BDEP-216 Discrete Input -

Schneider Modicon AS-H819-209 CHASSIES ASH819209

Schneider Modicon AS-BDAP-112 USPP ASBDAP112

Schneider Modicon ASB872002 Excellent Analog OUT Module AS-B872-002

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

Schneider Modicon AS-W801-006 ASW801006 Extender Cable NIB

Schneider Modicon 140CRA93100 / 140CRA 931 00

SCXI Accelerometer Input Modules NI SCXI-1531

RELEASE SuperMicro X9DRT-F MB ※Check W/ Us for Availability FIRST※

Siemens 6ES7 132-4BD00-0AA0 6ES71324BD000AA0 Output Module

SIEMENS SINUMERIK 840D/DE NCU 572.3 6FC5357-0BB22-0AE0

MODULE COMMUNICATION ALLEN BRADLEY 1203-GD1

SIEMENS SIMODRIVE 611 BOARD 6SN1118-0DJ21-0AA1NIB

SIEMENS SINUMERIK OP 010S 6FC5203-0AF04-0AA0 NIB

SIEMENS Caterpillar D6H / D6H Series II Tractors Service Manual 8KB 4RC 6FC

ALLEN-BRADLEY1756-OFCI/AOUTPUTMODULE1756-0FCI

Allen Bradley SLC 500 Output Module 1746-OX8 Ser. A

ABB ROBOT DSQC345B - RECTIFIER DC1 - 3HAB8101-2

A06B-0128-B575#7076 FANUC SERVO MOTORS REMANUFACTURED

0.1-1250 μm LPA-9Z Desktop Inbligent Laser Particle Size Analyzer Sizer

MODICON AS-M909-001 USPP ASM909001

ALLEN BRADLEY 1398-PDM-150B USPP 1398PDM150B

ADEPT TECH 10332-00500 USPP 1033200500

GE FANUC IC640WMI910 NSFP IC640WMI910

SIEMENS LMXD63B700 NSPP LMXD63B700

SIEMENS 6ES5-928-3UB12 USPP 6ES59283UB12

ALLEN BRADLEY 2755-DD1A-R1 NSFP 2755DD1AR1

Siemens 6ES5 928-3UB21 6ES59283UB21

Siemens SIMATIC 6ES5 926-3SA12

SIEMENS 6ES5-512-5BC12/6ES5512-5BC12 INTERFACE MODULE XLNT

Siemens 6ES5 441-4UA14/6ES54414UA14 Digital Input SEALED OFFERS ACCEPTED

SIEMENS 1FT6105-8SB71-1AA0 3-phase Brushless Servomotor

Siemens EM235 6ES7235-0KD00-0XA0 6ES72350KD000XA0

Schneider Digital Input Block Fuse 140CFB03200 3436

Square D 9006-PBF121

Siemens 6ES7460-0AA01-0AB0 SIMATIC S7-400 IM460-0 Transmitter Interface Module

WE SHIP SAME CISCO SLM2024T SG200-26 SLM2024T-NA 26PORT GIGABIT SMART

Siemens 6RA7018-6DV62-0-Z 6RA7018-6DV62-0 DC DRIVE

Siemens TP270-6 6AV6545-0CA10-0AX0 Touch Glass

Schneider Modicon TSX COMPACT HIGH SPEED COUNTER MODULE AS BZAE 201

Schneider Modicon AS-BDAP-210 Discreet Output Relay ASBDAP210

Schneider Modicon AS-B825-016 I/O Module Repaired

Schneider Modicon INPUT MODULE 16 PT ISOLATED AS-B817-216 FACTORY SEALED PACKAGE

Schneider Modicon Assy. Motion Module AS-B885-101

Schneider Modicon AS-BVIC-224 4Ch 24V 25KHz Counter Input VIC-224 ASBVIC224 VIC224

Schneider TCC-X1730-LW Operator Interface Panel

Siemens 6ES7 131-4BD00-0AA0 6ES71314BD000AA0 Input Module

RSP720-3CXL-GE Cisco Route Switch Processor 720-3CXL Router

Siemens Digital Output Module 6ES5 440-8MA22 TAKE-OUT

SIEMENS SINUMERIK 840C 6FC5103-0AE01-0AA1

Sammy AtomisWave Communication/Network Cartridge JAMMA PCB AW Module

SIEMENS 6SN1-162-0EB00-0AA0 NSPP 6SN11620EB000AA0

SIEMENS 6SC116111-2AA00-G600-D490/10-M6REQ SIMODRIVE

SIEMENS 6FC5-111-0CA02-0AA2 USPP 6FC51110CA020AA2

AllenBradley6182H-10TLH4DVersaViewCE1000HWorkstationPanel

Allen Bradley VersaView Display 17" to 19" Repair Service $169.99

ABB E2N-A16 600V 2000A PR121/P L/S/I INSULATED CASE CIRCUIT BREAKER

Adtech AX4000 LOADED WITH CARDS

(H13) 1 CUTLER-HAMMER LDB2600W SEALED BREAKER H13

KELLER TECHNOLOGY CORP 14449-5011 NSPP 144495011

ACUITY IMAGING 002-PV9040 USPP 002PV9040

FLUID POWER DIVISION PMC-20E USPP PMC20E

FANUC A06B-0143-B175 USPP A06B0143B175

SEIKO INSTRUMENTS & ELECS LTD OFL-760A-26 USPP OFL760A26

RAPID POWER TECH SPSAA100012 USPP SPSAA100012

RELIANCE ELECTRIC 86466-47T NSFP 8646647T

Siemens 6ES5 460-4UA13 -FS- 6ES54604UA13

Siemens 6ES5-928-3UA11 USPP 6ES59283UA11

SIEMENS 6ES5-430-7LA11 USPP 6ES54307LA11

Siemens 6ES5 490-7LB21 CONNECTOR IN BOX

Siemens S5 6ES5 464-8MC11

SIEMENS 802Dsl Membrane Keypad

SIEMENS 6ES7 223-1BL22-0XA8 EM 223 CN I/O MODULE

Square D 8005 MP-1

Nokia NIF4303FRU 2-Port X.21 PMC Interface Card Module

WS-F6K-DFC3A DIST FWD CARD-3A FOR 65XX 6816 MODULES WITH SUP720

SIEMENS 6ES7-151-1AA03-0AB0

Siemens SCD 1597-ET 6AV8100-1BB00-0AA0

Reliance 45C940

Schneider Modicon GOULD B805 AS-B805-016 INPUT MODULE 115 V AC

Schneider Modicon AS-B352-001 USPP ASB352001

Schneider Modicon AS-S908-021 USPP ASS908021

Schneider Modicon AS-B883-101

Schneider Modicon AS-B807-032 120VAC INPUT

MODICON AS-BDAP-210 DISCRETE OUTPUT MODULE

SIEMENS MODULE DIGITAL INPUT 505-4316A 5054316A

Siemens 6ES5 451-4UA13 -FS- 6ES54514UA13

Siemens PLC Output Module 6ES7 135-4FB01-0AB0 6ES71354FB010AB0 NIB

SIEMENS Control Rack 6FC3761-2FA Z_ Genumerik 3G Unit Sinumerik 6FC 3761

USB2.0 to RS232 TTL Data Communication Converter Module PL2303 +Free 4pcs cable

SIEMENS 6SN1118-0DG21-0AA1 _ 6SN11180DG210AA1 version A

SIEMENS SIMODRIVE 611 6SN1118-0DJ21-0AA1

SIEMENS 6FC5501-0AB11-0AA0 802CE Membrane Keypad

Advantech PCI-881 REV.3 board

ALLEN-BRADLEY 1770-T12 PLC-4 Microtrol Programmer WOW

ABB AUTOMATION Machine Terminal REM543CM214AAAB, REF542PLUS

Adept NSK EXC 90400-80020 3-Axis Controller 90401-20035 90401-10040 90400-02100

6SE7033-7TG60 SIEMENS MASTERDRIVE 370AMP 200kW 510-620VDC VECTOR CONTROL

HONEYWELL 51196886-100 NSPP 51196886100

SYMAX 8030-RIM-123 NSPP 8030RIM123

CUTLER HAMMER S811T18N3S USPP S811T18N3S

CONAIR 614-190-03 USPP 61419003

OLEC AL-53 USPP AL53

MITSUBISHI Q12H-CPU USPP Q12HCPU

GENERAL ELECTRIC 531X111PSHAPG2 USPP 531X111PSHAPG2

Siemens 6ES5 265-8MA01 HIGH SPEED SUB CONTROL N BOX

Siemens 6ES5-484-8AB11/6ES5484-8AB11 INPUT MODULE XLNT

SIEMENS 6ES5-312-3AB32 USPP 6ES53123AB32

Siemens 6ES5375-0LC11 6ES5 375-0LC11S5 MS375 Memory Submodule 2KB

Siemens 6ES5 535-3LB12 6ES5353LB12

Siemens 6FR2490-0AH11 99% , opened box, FreeShip

Siemens TP177 6AV6640-0CA11-0AX1 Touch Glass ping

Siemens 6ES5466-8MC11

KALATEL INTERFACE MODULE

YOKOGAWA P2ET6-20J USPP P2ET620J

SIEMENS 6ES7 214-1BC00-0XB0 6ES7214-1BC00-0XB0 FreeShip

Siemens OP27 6AV3 627-1LK00-1AX0

Potter and Brumfield CB-1001B-70

Schneider Modicon AS-B840-000 REED RELAY OUTPUT N.O. ASB840000

Schneider Modicon AS-584L-231 USPP AS584L231

Schneider Modicon AS-M84A-002 USPP ASM84A002

Schneider Modicon AS-9594-001 Memory Module P890 Executive Cartridge Lot of 3

Schneider Modicon AC POWER CONVERTER AS-P120-000 LOT OF 2

Schneider Modicon /Modicon/AS-BDEP-209 Input Module 8 pt

Siemens Texas 305-20N 30520N Input Module 85-128VAC

TELEMECANIQUE HMI XBT-N400 in Box

SIEMENS SIMATIC S7 ANALOG OUTPUT MODULE / 6ES7 332-7ND00-0AB0

SIEMENS 3NA1-224 USPP 3NA1224

SIEMENS SINUMERIK 840D/DE NCUBOX 6FC5247-0AA00-0AA2

Bogen Communications PCMTBM 2-Way Talkback Module/ Real Time Clock for PCM2000

SIEMENS Simodrive 6SN1145 1BA02 0CA0

SIEMENS PANELFRONT 6FC5203-0AF02-0AA0

Advantech PCI-1716L

Allen-Bradley 2711P-T12C4D1 PanelView Plus 1250 Touch/Enet/RS-232 64MB DC

ABB 5 KV Drawout Voltage Transber unit Advac DO MetalClad 40:1 PTG3-1-60-482F

ACE Technology Limited ACE-6243 Eye Safe Laser Range Finder

A5E00415900 SIEMENS INVERTER BOARD 1 Pc

83752B Agilent opt 1E5/ 1ED Signal Generator Synthesized Swept

SIEMENS 6FC3-551-1AC-Z USPP 6FC35511ACZ

ASEA BROWN BOVERI DSPC172H USPP DSPC172H

APW MCLEAN T50-1226-G106A NSPP T501226G106A

MITSUBISHI A6GPPE-115UL USPP A6GPPE115UL

INDRAMAT DDS02.1-W150-DS01-00 USPP DDS021W150DS0100

ALLEN BRADLEY 2711-K6C9 NSFP 2711K6C9

SONY DXC-930 USPP DXC930

Siemens 6ES5-417-7AA21 NSFP 6ES54177AA21

SIEMENS 6ES5 464-8MC11 6ES54648MC11

SIEMENS 6ES5 951-7LB21 6ES59517LB21 Power Supply

Siemens PLC OUTPUT MODULE6ES5 440-8MA21 WOW

Siemens 6ES7 350-1AH01-0AE0 6ES73501AH010AE0

SIEMENS PLC LOGO! 6ED1 053-1HA00-0BA0 24RL

PTZ Camera 680TVL B/W 550TVL Color Samsung Original Module 37X Optical

healy 1363A MC100-1 interface module with harness

V2DIP1-48 VNC2-48 USB host development module FTDI Flash drive interface

Siemens 6AV6545-0CC10-0AX0 Touchscreen Glass w/ Film

Siemens LOGO 24RC 6ED1052-1HB00-0BA2

Omega 4002-JF

Schneider Modicon B805 AS-B805-016 AC Input Module

Schneider Modicon AS-884A-301 MODULE AS884A301

Schneider Modicon AS-E902-151 NSFP ASE902151

Schneider Modicon GOULD B804 OUTPUT MODULE AS-B804-016

Schneider Modicon AS-B827

Schneider Modicon PLC Card Part AS-B825-016

Schneider/Telemecanique Twido PLC TWDLCAE40DRF in Box

Schneider Soft Starter ATS48D38Q 18.5KW

SiemensOperatorPanelCorosOP15-C16AV3515-1MA20-1AA0

Siemens 6AV6545-0CC10-0AX0 TP270 6AV65450CC100AX0 Fast Shipping

SIEMENS SIMADYN S5 MODULE PN 6DD2920-0A00

GE Fanuc IC693CMM311G Communication Control Module

SIEMENS SimoDrive Servo Drive Controller 6SN1130-1AD11-0GA0

SIEMENS Sinumerik 6FC5147-0AA07-0AA0. Cooling Fan 840C

SIEMENS MOORE 16114-1/04 APACS MODULRAC MODULE RACK CHASSIS 10 SLOT 24V 41462

Allen-Bradley Output Module 1746-OV16

AB 2711-K6C10 whole machine in good condition

ABACUS SPIRENT ZARAK CIRCUIT GENERATOR NETWORK SIMULATOR+ ACG(20)& PI MODULES

A06B-0374-B569#7076 FANUC SERVO MOTORS REMANUFACTURED

75 HP EMERSON US MOTORS ELECTRIC D75E1ES 230 460 V ODP 3570 RPM 364TS FRAME

RELIANCE ELECTRIC 802220-14VC USPP 80222014VC

ALLEN BRADLEY 2750-AHD NSPP 2750AHD

ALLEN BRADLEY 1771-OFC NSFP 1771OFC

HONEYWELL R7510-B1003-4 USPP R7510B10034

WONDERWARE OICB-15S-2CMXU USPP OICB15S2CMXU

TOTAL CONTROL PRODUCTS QPI-21100-S2P USPP QPI21100S2P

GIDDINGS & LEWIS 503-26683-01-R0 USPP 5032668301R0

Siemens 6ES5-241-1AA11 USPP 6ES52411AA11

SIEMENS 6ES5 375-1LA15 6ES5375-1LA15 MEMORY LNC QUANTITY

SIEMENS BOARD 6ES5-900-0AA12 6ES5 900 0AA12 3 NET 807 1070 001 BL2A SIEMEN

Siemens 6ES5 981-0JA11 NSFP 6ES59810JA11

SIEMENS 6ES5-430-4UA11 6ES54304UA11

Siemens MP270 6AV6 542-0AC15-2AX0 Membrane Keypad

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Texas Instruments 500-5020

Spirent Adtech SX/12-1 Data Link Channel Sim. w/ DS1 T1 Interface Module

Uson Corp I/O Module 403-X300G 403-X300G

Siemens C98043-A7002-L4

Modicon AS-W801-001

Schneider Modicon AS-P120-000 AC POWER CONVERTER 65

Schneider Modicon AS-B872-100 ANALOG CURRENT OUTPUT MODULE

Schneider Modicon AS-BDAP-216N NSPP ASBDAP216N

Schneider Modicon AS-B883-001

Schneider Modicon TSX COMPACT M AS-BDAU-202 ~SUR.~

Schneider Modicon B824 24 VDC Output True High - AS-B824-016

Schneider Modicon TM238LFDC24DT

Schneider TSXDEY64D2K Premium Sink Connection Input Module

RELEASE SuperMicro X9DBL-IF Motherboard CHECK W/ US FOR AVAILABILITY