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國內的包裝生產線在發展初期一般只能完成物料包裝，后續的搬運工作則由搬運工人來完成。隨著產量的日益擴大，傳統的人工搬運方式顯然無法滿足需求，碼垛機械的出現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，使生產現場變得智能化，可以實現飲料、食品、日化等行業各種作業的碼垛物流，為企業改善工作條件，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，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。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，且通過觸摸屏可設定不同的層數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需要確認是否轉向 ( 如需轉向則轉向氣缸動作 ) 并計數，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提供棧板，依次循環實現持續碼垛。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 點數較多 (DI 為 75，DO 為 40)，以及電控柜空間限制的需求，在系統選型時采用西門子 S7-200 SMART PLC 作為主控制器，因為 S7-200 SMART 具備 60I/O 的大點數 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，單線系統選用7寸屏即能滿足要求，但對于雙線控制系統，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、系統復位及數量清零等子程序組成，如圖 3 所示。

ALLEN BRADLEY 2711-K6C1 NSPP 2711K6C1

ALLEN BRADLEY 1756-M13 NSPP 1756M13

Siemens 6ES5 951-7ND51 6ES59517ND51

SIEMENS 6ES5 451-7LA11 6ES54517LA11

SIEMENS 6ES5-453-4UA11 6ES5453-4UA11

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Siemens 6ES7291-8GE20-0XA0 Memory Module

Siemens SIMATIC S7-400 6ES7 412-2XG00-0AB0 CPU 412-2

Reliance 803612-SE

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(000 BACK AL)1 NIB SIEMENS 6SE7031-0EE60 6SE7090-0XE87-3AC0 CONVERTER DRIVE

IMPERIAL 08134600 USPP 08134600

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HONEYWELL 30734558-001 USPP 30734558001

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YASKAWA ELECTRIC DISCT-J1040 USPP DISCTJ1040

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Siemens OP37 6AV3 637-1ML00-0FX0 Membrane Keypad

Reeves SBAI-1001-11

Schneider Modicon AS-B807-032 ASB807032 32 Point 120 VAC Input

Schneider Modicon AS-884A-201 PROCESSOR MODULE AS884A201

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Schneider Modicon AS-5540-003 Bus Duct

Modicon TSX Quantum 24-230 VAC Output Module 140DAO84000

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SIEMENS SINUMERIK I/O MODULE 6FC5611-0CA01-0AA0

SIEMENS 6SN1123-1AA00-0EA0 6SN1 123-1AA00-0EA0 SIMODRIVE 611 160A Ver D

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SIEMENS HMI 6FC5253-6BX10-2AFC PCU 50 566mHZ6FC5210- 00F20-0AA0840D BS003

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Acterna ANT-20

6962ED2580A2 Starter CUTLER HAMMER

8520CPUX ALLEN BRADLEY ELECTRONIC CIRCUIT BOARD REMANUFACTURED

SIEMENS 6SE3-221-3DC40 USPP 6SE32213DC40

AVTRON AFS110-4CN0-C USPP AFS1104CN0C

ASEA BROWN BOVERI MSB63800L NSFP MSB63800L

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INDRAMAT MDD071C-N-030-N2S-095PB0 NSFP MDD071CN030N2S01

ASEA BROWN BOVERI ACH401601632+A0BE0000 USPP ACH401601632A0BE

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Siemens 6ES5-441-7LA13/6ES5441-7LA13 OUTPUT MODULE NIB

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SIEMENS S5 6ES5 310-3AB13 6ES53013AB13

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Omron 3G2A5-PS221E

Schneider Modicon AS-M84A-102 ASM84A102 CPU Processor NIB

Schneider Modicon MEMORY BOARD AS-506P-F12 REV C21 /REPAIRED

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Schneider Modicon GOULD/ MODULE - AS-B814-001

Schneider Modicon AS-BDEO-216 INPUT MODULE ASBDEO216

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YASKAWA ELECTRIC CPCR-AN051B NSPP CPCRAN051B

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Texas Instruments 505-4632

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Modicon DB-043505843

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Schneider Modicon AS-BDAP-217 Output Relay ASBDAP217

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0300P-4NAN-0001 REULAND AC SERVO SPINDLE

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RME FireFace800 Fireface 800 PROAUDIOSTAR

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AllenBradley2711-K9C9PanelView900OperatorInterfaceSeriesCRev.A

Allen Bradley Versa View 1700P - 6181F-17TPXPH Series D

ABB INVERTER MODULE DRIVE ACS600 ACS 600 ACN634 ACN6340100600000300902

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(no lot#) Allen Bradley SMC Dialog Plus Drive 150-B180NBD 180A

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MODICON ANALOG OUTPUT MODULE AS-B872-011

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