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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。

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Reliance 45C340

Schneider Modicon GOULD REMOTE I/O RECEIVER MODEL AS-J821-001

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SIEMENS S5 6ES5 421-8MA11 Digital Input Module8DI 24V

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Advantech PCA-6186VE PCA-6186 Rev.A1 NIB

Allen-Bradley 1771-OA AC OUTPUT MODULE

ABB ASEA BROWN BOVERI POWER ITE AIR CIRCUIT BREAKER 800A 800 AMP KDON K-DON 800S

ADEPT 90400-60131 AMPLIFIER MODULE MEGATORQUE 300 WATT CONTROLLER

6SE7026-0TP50 SIEMENS COMPACT + MASTERDRIVE 59AMP 30kW 510-620VDC MOTION CNTRL

SYMAX 8020-SCP-424 NSPP 8020SCP424

CUTLER HAMMER IDT0286 NSFP IDT0286

CLEVELAND MOTION CONTROL BNR5110GPA00CS0002 NSPP BNR5110GPAOOCS00

NEMATRON CORP IWS-4824 USPP IWS4824

MITSUBISHI FR-A520-2.2K-NA USPP FRA52022KNA

GE FANUC 44A719348-102 USPP 44A719348102

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SIEMENS S5 SERIAL INTERFACE 6ES5 521-8MA21

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Jova Solutions TIMS-0102 USB 12C/SPI Interface Module

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Siemens OP17 6AV3617-1JC20-0AX1 Membrane Keypad , ping worldwide

Patriot WA0750

Schneider Modicon AS-B872-002/ASB872002 Output Module OFFERS ACCEPTED

Schneider Modicon AS-5540-006 NSFP AS5540006

Schneider Modicon AS-M680-108 Memory Module

Schneider Modicon AS-9490-004 USPP AS9490004

Schneider Modicon 800 SERIES 11 SLOT RACK AS-H827-103

Schneider Modicon TSX COMPACT DISCRETE INPUT DEP 216 AS-BDEP-216 LOT OF 5

Siemens TI 505-4108 Low VDC Input Module

Telemecanique ATV11HU09M3A 0.37kW Inverter in Box

SIEMENS SIMATIC SM422 DIGITAL OUTPUT MODULE S7-400 ++

SIEMENS 4700 POWER FUNCTIONS METER OPERATOR INTERFACE PANEL 4700-BDRMC3-11HN

SIEMENS Sinumerik 840C/840CE P/Supp 6FC5114-0AA01-1AA0

CC LINK COMMUNICATIONS MODULE MITSUBISHI FR-E5NC

SIEMENS SIMODRIVE 6SN1145-1AA01-0AA1SINUMETIK 840D NCU-BOX 6FC52476FC5357 6SN

SIEMENS Servo Drive 6FC5247-0AA00-0AA3 6FC52470AA000AA3

Advantech PCA-6184V, no ethernet port,

Allen-Bradley 2711-T6C15L1 Panelview 600

ABB 3HNE00313-1

ACCURAY AIC8 086155-001 SCANNER MODULE CARD CONTROLLER B211850

A2LA 17025 Accredited Calibration with full Data Report

82-1/2" OVER ALL LENGTH 2-1/4" DIAMETER BALLSCREW 55" TRAVEL 5-1/2" FLANGE

SIEMENS 6ES7-623-1DE01-0AE3 USPP 6ES76231DE010AE3

ASEA BROWN BOVERI 750191-001B NSFP 750191001B

ALSTOM ALSPA-MV-1013 USPP ALSPAMV1013

MICRO MOTION DL065-S242SU NSPP DL065S242SU

HUB CITY 88 NSFP 88

ALLEN BRADLEY 1774-KA USPP 1774KA

SIEMENS 6ES5-925-3SA11 USPP 6ES59253SA11

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SIEMENS 6ES5 465-7LA13 Module

Siemens PLC 6ES5-451-4UA12/6ES54514UA12 Output

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Siemens PLC 6ES7 338-4BC01-0AB0 6ES73384BC010AB0 NIB

PVDM3-32 CISCO 32-CHANNEL HIGH-DENSITY VOICE AND VIDEO DSP MODULE

GSM/GPRS Modem Pool 8 Ports USB interface Wavecom Module AT Commands Q2406

Unico 314-739 314739 Interface Module No Box

Siemens 6AV6 640-0DA11-0AX0 Touch Panel NIB

Siemens Logo 230RC 6ED1 052-1FB00-0BA3

MTT ms2304

Schneider Modicon Connector/Cable AS-W801-002/ASW801002

Schneider Modicon 800 SERIES AS-H827-103 11 PORT RACK ASH827103

Schneider Modicon AS-E685-904 NSFP ASE685904

Schneider Modicon Gould AS-B804-016 OUTPUT MODULE 16POINT 115VAC ANALOG

Schneider Modicon AS-B804-016

Schneider Modicon Output Module True High AS-B820-008

Schneider TWIDO TWDNOZ485T Expansion, Comm, RS485 Tbk

Schneider Modicon TSXPCX1031-C TSXPCX1031C PLC Cable

SiemensSimatic6AV6641-0CA01-0AX16AV66410CA01

Siemens 6AV6642-0BC01-1AX0 6AV6 642-0BC01-1AX0 SIMATIC TP177B 6" Touch Panel

SIEMENS S5 6DD2920-0AS0 INTERFACE MODULE PULSE CIRCUIT

GE Fanuc IC697RCM711C Redundancy Communications Module

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SIEMENS SINUMERIK 6FC5203-0AF02-0AA1

SIEMENS MOORE 750E111GNNNF ELECTRONIC PNEUMATIC VALVE POSITIONER AIR 750E 20113

Allen-Bradley Panel View 600 Plus

AB 1336E-B015-AA-EN 460V 15HP IMPACT DRIVE QUANTITY TESTED

ABB/ACS 500 150 HP Drive 440-500 VAC Cat# H502125400P2BBB200 3000

A06B-0332-B069#7000 FANUC SERVO MOTORS REMANUFACTURED

75 HP ELECTRIC MOTOR 1200 RPM 405T FRAME NEMA PREMIUM EFFICIENT SEVERE DUTY

RELIANCE ELECTRIC 6V41-096TA NSPP 6V41096TA

ALLEN BRADLEY 2711-K14C1 USPP 2711K14C1

ALLEN BRADLEY 1771-IF05 USPP 1771IF05

HONEYWELL 30731737-006 NSFP 30731737006

WESTINGHOUSE DBL-25-1200 USPP DBL251200

TEXAS INSTRUMENTS PLC VPU500-3104 USPP VPU5003104

GENERAL ELECTRIC DS3800DMEC1D1D USPP DS3800DMEC1D1D

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

SIEMENS 6ES5 375-0LC31 6ES53750LC31

SIEMENS 6ES5-988-3NA11 USPP 6ES59883NA11

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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 Intelligent Laser Particle Size Analyzer Sizer

MODICON AS-M909-001 USPP ASM909001

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ADEPT TECH 10332-00500 USPP 1033200500

GE FANUC IC640WMI910 NSFP IC640WMI910

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SIEMENS 6ES5-928-3UB12 USPP 6ES59283UB12

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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 TP27-10 6AV3 627-1QL00-0AX0 Touch Glass, Bergquist Touch Products

Schneider Modicon TSX COMPACT DISCRETE OUTPUT AS-BDAP-210 4

Schneider Modicon ASBDAP210 AS-BDAP-210Compact output

Schneider Modicon AS-B825-016 NSFP ASB825016

Schneider Modicon MODULE AS-E908-131 S35D

Schneider Modicon AS-W192-015

Schneider Modicon AS-BZAE-204 HIGH SPEED COUNTER IN BOX FACTORY SEALED

SCHNEIDER TC2000 OPERATOR INTERFACE 3515 KPM PARTS/REPAIR BROKEN NOB

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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

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FLUID POWER DIVISION PMC-20E USPP PMC20E

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

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SIEMENS 802Dsl Membrane Keypad

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

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

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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