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國內的包裝生產線在發(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線中，使生產現(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(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(yè)。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(qū)，且通過觸摸屏可設定不同的層數(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(tǒng)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(jù)需要確認是否轉向 ( 如需轉向則轉向氣缸動作 ) 并計數(shù)，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(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(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(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(tǒng)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(shù)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(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)復位及數(shù)量清零等子程序組成，如圖 3 所示。

SCHNEIDER 140DAI55300 TSX QUANTUM 140-DAI-553-00 in Box

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Siemens OP-393 II 6ES5 393-0UA12 OP393 6ES5393-0UA12

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SCHNEIDER ELECTRIC SR2 COM01 SR2COM01 12-24VDC ZELIO COMMUNICATION MODULE

Ethernet Communication Module USB SPI ENC28J60 Remote

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SIEMENS MOORE SPA SITE PROGRAMMABLE PROCESS ALARM SPA HLPRG 4PRG U-AO

Allen-Bradley 855PDB24MEH4322 Operator Indicator Light 24VAC/DC Red/Green

ABB 1400 M94 robot, robot, Motoman robot, Nachi

AC, 120V OUTPUT MODULE, OUTPUTS, 16

A06B-6058-H229 SERVO AMPLIFIER 2AXES FANUC

8" LCD 800x600 Video Zoom Microscope 3.3x-147x w/ Boom Stand

SEW EURODRIVE MDV60A0450-503-4-00 NSPP MDV60A0450503400

ALLEN BRADLEY 6724-PLX2 USPP 6724PLX2

ALLEN BRADLEY 2760-RB NSFP 2760RB

INTEGRAL TECHNOLOGIES 3378-00480 USPP 337800480

GENERAL ELECTRIC DS3800HMPJ1A1A USPP DS3800HMPJ1A1A

YAMATAKE 82114930-002 USPP 82114930002

MELLTRONICS 222-8360 USPP 2228360

Siemens 6ES5-304-3UB11 NSFP 6ES53043UB11

SIEMENS 6ES5 430-4UA11

SIEMENS S5 6ES5 373-1AA41 Memory Submodule

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Texas Instruments 5TI-2000

Telemecanique Starter Interface Module LA1LC180BD

TSXSAY100 Modicon Premium AS I Module TSX SAY 100

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Modicon MM-PMA1-200

Schneider Modicon Gould AS-J890-001 Remote Interface I/O PLC Processor

Schneider Modicon AS-BADU-205 Compact Analog Input ASBADU205

Schneider Modicon AS-BMOT-202 USPP ASBMOT202

Schneider Modicon AS-C484-265

Schneider Modicon AS-BDAP-210 8 POINT OUTPUT MODULE

Schneider Modicon High/Low Density Connector AS-8534-000

Schneider TELEMECANIQUE PLC TSXDET824 in Box

Schneider Automation Input Module TSX DET1612

PWR-7200/2-DC CISCO 7200 REDUNDANT DC 24V-60V POWER SUPPLY OPTION

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SIEMENS 6DD1-640-0AC0 USPP 6DD16400AC0

LG G4L-CUEA G4LCUEA PLC Communication Module

SIEMENS SIMODRIVE 6SN1130-1A011-0BA0

SIEMENS SINUMERIK 840C NC CPU 6FC5110-0BB01-0AA2

SIEMENS SERIES 760 VALVE CONTROLER MODEL 760P15BAANNNB4

ALLEN-BRADLEY SLC 500 1746-OW8 OUTPUT MODULE QTY

ALLEN BRADLEY RIGHT HAND DOOR HARDWARE KIT 1494V-L3

ABB SACE F1H CIRCUIT BREAKER 3P POLE 1250A 800A AMP PROTECTION TRIP PR1/P 21521

A06B-0148-B175#0008 FANUC SERVO MOTORS REMANUFACTURED

7 AMAT 0021-35087 PLATE, BLOCKER, N2/HE CARRIER GAS, DXZ, UNIV. shower head

PACIFIC SCIENTIFIC M5HHON-00091-00 NSPP M5HHON0009100

ALLEN BRADLEY 1771-IR FNFP 1771IR

ALLEN BRADLEY 1336S-B010-AA-EN-L6 NSPP 1336SB010AAENL6

GENERAL ELECTRIC DS215SDCCG1AZZ01B USPP DS215SDCCG1AZZ0B

TELEMECANIQUE ATV-452D15 USPP ATV452D15

SQUARE D HCN23744M NSFP HCN23744M

CUTLER HAMMER 4144H304 USPP 4144H304

Siemens 6ES5 951-7NB13 6ES59517NB13

Siemens S5-95U L2 DP SLAVE PLC 6ES5-095-8MD01

SIEMENS 6ES5-752-0AA22/6ES5-752-0AA22 INTERFACE SUBMODULE NIB

Siemens 6ES5 498-1AA31 USPP 6ES54981AA31

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RSP-16 CISCO 7500 ROUTE SWITCH PROCESSOR 16 SPARE

Telemecanique TSX07312428

SIEMENS Simatic 6ES5525-3UA11 Comm. Interface Module

WAGO 750-485 750485 2-Channel Analog input Module 4-20 mA Ex i

Siemens 6SL3 211-0AB17-5UB1 6SL3211-0AB17-5UB1

Modicon AS-P530-OMA

Schneider Modicon Electric AS-BDAP-217 FACTORY SEALED

Schneider Modicon ASB248 ASB248501 Output Module AS-B248-501

Schneider Modicon AS-B875-001 USPP ASB875001

Schneider Modicon AS-B829-116 MODULE

Schneider Modicon Gould AS-B350-001

Schneider Modicon AS-J890-001 Remote I/O Processor

Schneider Automation TSX-DST1632 Output Module TSXDST1632 Warranty

SIEMENS 505-6108B ANALOG INPUT MODULE 5056108B

Reliance Electric Remote I/O Interface 45C37B

SIEMENS 7Pu4020-0AN20 USPP 7PU40200AN20

SIEMENS Sinumerik NCU 6FC5357-0BA33-0AE0

Prosoft MVI56-BAS MVI56BAS Communications Module

SIEMENS Module 6SN1123-1AA00-0HA2 (6SN11231AA000HA2)NIB

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D 6FC5247-0AA00-0AA26SN1123

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

AllenBradley2706-E43J32B1DatalinerPanel

Allen Bradley Terminal Board 9101-1780 Amphenol /Sealed

ABB ISOMAX 3 POLE 400 AMP MOLDED CASE CIRCUIT BREAKER S5HQ400BW

ZEBRA 113-701-00200 USPP 11370100200

(S2-5) 1 MOOG-ATCHLEY 215A-310 SERVO VALVE. S2-5.

MITSUBISHI FR-A740-00860-TF USPP FRA74000860TF

ALLEN BRADLEY 1336VT-B040-EAR-FA2-L3-S1 NSFP 1336VTB040EARFA2

GENERAL ELECTRIC 531X302DCIBDG4 NSPP 531X302DCIBDG4

FISHER ROSEMOUNT 6853454-094 USPP 6853454094

SIEMENS 6ES5-923-3UC11 USPP 6ES59233UC11

REXROTH 0608841030 USPP 0608841030

TEXAS INSTRUMENTS PLC VPU-200-3102 USPP VPU2003102

Siemens 6ES5 524-3UA13 -- 6ES55243UA13

Siemens 6ES5-984-2UB11/6ES5984-2UB11 SIMATIC S5 ADAPTER NIB

SIEMENS 6ES5-451-7LA12/6ES5451-7LA12 OUTPUT MODULE RFB

Siemens 6ES5 350 5AA21 6ES5 350 5AA21 PLUS 2 X 6ES5980 4AA11 ALL

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Siemens C98043-A7010-L1

Siemens 6ES5 430-4UA14 -FS- 6ES54304UA14

Square D 8030 DLM-110

Schneider Interface Module 140 ESI 062 10 ASCII 3572

WITH 3 YEARS HP ON-SITE . Win7.WEBCAM.DVDRW

Siemens 6ES7901-1BF00-0XA0 TP27 Download Cable FreeShip

SIEMENS touch panel 6AV3627-1QL01-0AX0 TP27-10

Shawmut TRS250R

Schneider Modicon ASH819209800 Series Rack AS-H819-209

Schneider Modicon AS-B572-010 USPP ASB572010

Schneider Modicon Controller AS-B875-101

Schneider Modicon AS-H819-100 RACK SECONDARY 7SLOT 19INCH ASH819100

Schneider Modicon AS-B842

MODICON 24VDC OUTPUT MODULE B232 501

Siemens 6FL7820-8CB10 input point module AFI5100 rev B H2

Schneider Modicon 140-DDO-843-00 140DDO84300 DC Out NIB

Siemens MODULE 200 X 8POINT 24VDC 5PIN 6ES7-141-1BF10

SIEMENS SINUMERIK 6FX1118-4AA01 CONTROL CARD

Siemens Simatic S7 6ES7 341-1AH01-0AE0 CP341 Communication Module - Serial

SIEMENS 6SN1123-1AA00-0HA1 6SN1 123-1AA00-0HA1 SIMODRIVE 611 Power Module 8A 1Ax

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SIEMENS 6FC5-210-0DA20-2AA1 USPP 6FC52100DA202AA1

AllenBradleyVersaView1000PPanelViewTouchScreen

Allen-Bradley 12 to 120V AC Output Module 1771-OAD - B

ABB Circuit Breaker 80 Amp Sace S3 Shunt Trip/Ground Fault Auxiliary Switch

ADEPT TECH 30846-00020 USPP 3084600020

(4398) Nachi PC Robot Control Board UM837A (4398)

INDRAMAT MAC1120-2-HD-4-C/130-A-0/W-I520LX/S005 NSPP MAC11202HD4C130A

TOSHIBA VT130G1-4330R0H USPP VT130G14330R0H

FANUC A06B-6041-H008 USPP A06B6041H008

DANFOSS 175H4425 USPP 175H4425

RELIANCE ELECTRIC 3RA2003 USPP 3RA2003

MTS SYSTEMS CO MPM1902FRM-418 USPP MPM1902FRM418

MAGNETEK C21-A50VT NSFP C21A50VT

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Siemens 6SA 8110-7AC00

Metasonix R-60 Self-Tuning MIDI-CV Interface Eurorack Module

XENPAK-10GB-ZR 10GBASE-ZR XENPAK MODULE for CISCO

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Reliance 0-52001

Schneider Modicon AS-984A-816 PLC

Schneider Modicon AS-B224-001 NSFP ASB224001

Schneider Modicon AS-P530-0MA POWER SUPPLY REPAIRED

Schneider Modicon AS-B804-116 Output Module 115VAC

Schneider Modicon AS-B266

Modicon PanelMate Plus MM-PM10300C 92-01685-00 ! WOW !

Siemens Simatic PLC Digital Input Module S7-321

Siemens 6ES7 322-1FH00-0AA0 -FS- 6ES73221FH000AA0

Siemens Simatic 8 Moble Operator Interface Panel 277 HMI w/ Stop Boxed A

SIEMENS 6DD1611-0AD0 MEMORY MODULE /BOX

SIEMENS SINUMERIK SIROTEC MODULE 6FX1190-1AA00

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ADLink NuDAQ ACL-6128A Isolated Analog Output Card NIB

ALLEN-BRADLEY 1791-0A32 Block I/O 120V AC 32 Point Module 32 Output

ABB ACS 600 AC AUTOMATION INC MULTIDRIVE 250HP

Active EMC broadband antenna 30MHz to 1GHz BicoLOG 30100 X, , biconical

6ES7316-1AG00-0AB0 6ES7316-2AG10-0AB0 Brand , Factory Sealed,

9 UNIT 1660 MFC, UFC-1660, CF4, H2, Cl2, N2, HBr, SF6, different gas range.

SIEMENS CLD63B600 NSPP CLD63B600

BOSCH 1070071221-102 USPP 1070071221102

BAILEY CONTROLS IEPEP-03 USPP IEPEP03

MODICON AS-P453-641 USPP ASP453641

JOHNSON CONTROLS JNCA NSFP JNCA

CONTROL SYSTEMS 7718-C USPP 7718C

Siemens 6ES5 095-8MA03 6ES50958MA03

Siemens 6ES5-458-4UA12 USPP 6ES54584UA12

SIEMENS 6ES5 777-0BB00 6ES57770BB00

SIEMENS S5 6ES5 465-7LA13 6ES5465-7LA13

Siemens S5-95U CPU 6ES5 095-8MB04 6ES5095-8MB04

SIEMENS 6ES7223-1HF00-0XA0

SIEMENS SIMATIC OP3 6AV3 503-1DB10 Operator Panel

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HP AGILENT 35651C INTERFACE/SIGNAL PROCESSOR MODULE

WS-X6704-10GE Cisco 6500 10 Gigabit EN Interface Module 4 ports

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Omron C200H-OD211

Schneider Modicon AS-C484-266 ASDC484266 Programmable Controller

Schneider Modicon ANALOG INPUT AS-B875-111 OUT OF BOX

Schneider Modicon AS-J471-600 USPP ASJ471600

Schneider Modicon 24 VDC INPUT AS-B827-032

Schneider Modicon AS-W512-003

Schneider Modicon ZAE-201/AS-BZAE-201 High Speed Counter 1X50/500KHZ ASBZAE201

SM321 16DI 24VDC INPUT MODULE 6ES7-321-1BH02-0AA0

Schneider TELEMECANIQUE XBT-GT-2110 XBTGT2110 with cable

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ECDL Syllabus 5.0 Module 7b Communication Using Ou.....

SIEMENS Simodrive LT-Modul INT. 15A 6SN1123-1AA00-0AA1

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5357 BBE

Adlink CPCI-R6780

ALLEN-BRADLEY 800MB-CPB16RAS PUSH BUTTON

ABB 1MRS090416-AAA REA 101 ARC PROTECTION RELAY SYSTEM MAIN MODULE 57976

ACCU SORT 22E8SL NSFP 22E8SL

A06B-6066-H003 FANUC SERVO AMPLIFIER REMANUFACTURED

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SIEMENS 3SF7834-6PB00 NSFP 3SF78346PB00

ALLEN BRADLEY 8520-3S10A-BAT-EX4-T1-Y-4-5-7 USPP 85203S10ABATEX4T

ALLEN BRADLEY 6008-LTV USPP 6008LTV

JOHNSON CONTROLS MS-NAE4510-2 USPP MSNAE45102

GENERAL ELECTRIC DS3800NFCD1S1J USPP DS3800NFCD1S1J

YASKAWA ELECTRIC CACR-SR-44SZ1SDY38 NSFP CACRsR44SZ1SDY38

MITSUBISHI MR-J2-100C USPP MRJ2100C

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SIEMENS 6ES5 430-7LA12 DIGITAL INPUT MODULE

SIEMENS S5 6ES5 456-4UA12 Digital Output Module

Siemens Digital Output Module 6ES5 454-7LA12 22516

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