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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。

SIEMENS 505-4208A INPUT MODULE 5054208A

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AllenBradley2711-K10G16/C2711K10G16Panelview

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Samsung LT133X2-154

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ADVANTECH SOM-A2552

ALLEN-BRADLEY 160-P1 PROGRAMMING TERMINAL KEYPAD ""

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88248

ADEPT TECH 10332-12410 NSPP 1033212410

(12) Hoffman A36X2E5410 Control Panel Enclosures 36" x 54.5" x 11.5"

INDRAMAT DDS03.2-W/030B USPP DDS032W030B

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EPSON E2L653S-UL USPP E2L653SUL

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RELIANCE ELECTRIC 0-51879-5 NSFP 0518795

MODICON AS-P933-007 NSPP ASP933007

INGERSOLL RAND 2133A99G02 USPP 2133A99G02

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LOT 8__Belkin OmniView Quad-Bus Server Interface Module PS/2 F1DE101A-AP

Yamaha Motif XF8 Synthesizer

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Reliance 0-51816-1

Schneider Modicon AS-B801-000 Slot Filler Plate

Schneider Modicon AS-9487-004 USPP AS9487004

Schneider Modicon AS-P421-010 USPP ASP421010

Schneider Modicon AS-B550-001 B550001 ASB550001 B550-001

Schneider Modicon AS-884A-301 Processor Module AS884A301 UVG

Modicon Square D XBT-F024110 XBTF024110 Operator Interface

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Advantech SOM-2353 SOM-2353F

Allen-Bradley 2711-B5A5 Series H Panelview 550 Touchscreen FRN 4.46

ABB AC Drive ACS601-0011-4-000B1200801 3PH 380-500 VAC - Extrusion Spare Parts

Acterna JDSU T-Berd FST2000 TestPad - FST-2310 OC3/12/48 90

6ES7147-1AA01-0XB0 Brand , Factory Sealed,

857-0055-BH011236C058 MODICON SERVO MOTORS REMANUFACTURED

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BAILEY CONTROLS NMFC-03 NSFP NMFC03

ATLAS COPCO 9032-0118-46-0001 USPP 90320118460001

MODICON AS-584A-042 USPP AS584A042

INDRAMAT TRANS01.7/1/PO00 USPP TRANS0171PO00

BANNER ENGINEERING MSXLHDE7212Y NSPP MSXLHDE7212Y

WINTRISS MACHINE CONTROL 3LC48-R USPP 3LC48R

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Allen-Bradley AB Panelview 1000 Cat 2711-K10C1

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AC Tech Variable Speed AC Motor Drive

A06B-1571-B123/0024-R FANUC AC SERVO SPINDLE REMANUFACTURED

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XYCOM 9462-0132120016002 NSFP 9462013212001600

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Allen Bradley Selectable Output Module 1771-OW WARRANTY

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0-57411-2E

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GENERAL ELECTRIC DS200IIBDG1ADA USPP DS200IIBDG1ADA

SYMBOL TECHNOLOGIES VRC6940-00V651US USPP VRC694000V651US

SORENSEN SGA-160/31D0-OAAAAB USPP SGA16031D0OAAAAB

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Schneider Modicon 800 I/O 32PT 115V MODULE AS-B806-032

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Schneider Modicon DEP218/AS-BDEP-218 DISCR. INPUT 16PT

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SIEMENS 6FC3984-3RA SINUMERIK 800 SERIES I/O MODULE

allenbradley2711-b6c5operatorsinterfacepanelview600

ALLEN BRADLEY TERMINAL LUG KIT 199-LF1

ABB IRB 6400 Water Jet Robot

Advanced Micro Instruments Oxygen Analyzer Panel Mount 115/230V 50/60Hz

(Q6-2) 1 ALLEN BRADLEY 1336F-BRF10-AN-EN-HAS2-L4E CONTROL MODULE Q6-2

MICRO MOTION DS100S128 USPP DS100S128

ALLEN BRADLEY 1336S-A020-AA-EN4-HA1-L6 USPP 1336SA020AAEN4HA

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