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国内的包装生产线在发展初期一般只能完成物料包装，后续的搬运工作则由搬运工人来完成。随着产量的日益扩大，传统的人工搬运方式显然无法满足需求，码垛机械的出现为这一问题提供了有效的解决方案。
　　码垛机可以集成在生产线中，使生产现场变得智能化，可以实现饮料、食品、日化等行业各种作业的码垛物流，为企业改善工作条件，减轻个人体力劳动，减员增效起到了关键作用。目前主流的控制系统采用 PLC+ 机械手的方式，对整条生产线的末端产品进行整理、堆叠、整垛输出等。
　　目前市场上主流的码垛线为单线输送系统，码垛能力在 30~40 箱 / 分，具体的码垛能力视货物而异。本项目中设计的码垛线为双线输送，码垛能力能达到 60 箱 / 分，主要应用在食品行业。该码垛线通过 PLC 控制将两条生产线上输送过的产品分别输送到对应的堆叠区，且通过触摸屏可设定不同的层数采用不同的堆叠方式，如第 1 层按方式 1 堆叠，第 2 层按方式 2 堆叠，码垛方式灵活。
　　2 工艺要求
　　码垛线分为 A、B 两线，每条线均由以下部分组成：入口输送带 1、入口输送带 2、入口输送带 3、分离电机、转向电磁阀、转向滚筒、堆叠输送带，出口输送带等;A、 B 两线共用栈板供应系统和左右栈板输送带等设备。码垛线装备实物图片如图 1 所示。
货物由入口输送带1进入，经过三个入口缓存输送带，输送到分离电机处;分离电机分离后根据需要确认是否转向 ( 如需转向则转向气缸动作 ) 并计数，PLC 进行判断产品是否已完成一列。达到一列后控制推杆动作，将货物整平。此时，PLC 发出 DO 信号给 ABB 机械手 (ABB 机械手与 PLC 通过硬接线连接 )，机械手动作抓取已完成码垛的一列产品;当完成一垛后，堆叠电机动作，将已完成堆垛的货物整垛输出;然后栈板供应启动，为缺少栈板的堆叠区提供栈板，依次循环实现持续码垛。其工艺流程如图 2 所示。
　3 自动化平台选型
　　鉴于该码垛机 I/O 点数较多 (DI 为 75，DO 为 40)，以及电控柜空间限制的需求，在系统选型时采用西门子 S7-200 SMART PLC 作为主控制器，因为 S7-200 SMART 具备 60I/O 的大点数 CPU 以及高密度扩展模块，并且模块体积紧凑，能够有效满足以上需求。码垛线上的转向气缸、滚筒等动作频繁，高达 20~30 次 / 分，故采用晶体管输出类型，外接中间继电器驱动大负载。在HMI选型上，单线系统选用7寸屏即能满足要求，但对于双线控制系统，需要显示的信息更多，最终选用 10 寸屏。同时，屏上集成的以太网接口与 S7-200 SMART 无缝连接，编程调试、设备通讯都很方便。电控系统配置如附表所示。
4.1 结构化模块设计
　　由于码垛线控制点数较多，程序较大，而且各部分功能较为分明，所以在软件设计时，采用结构化编程的理念可使程序结构更加分明。程序设计分为主程序和子程序两部分，主程序中 AB 两线运行各自调用相应子程序。子程序主要有：开机初始化程序、各设备手动控制程序、入口计数子程序、整列推杆初始化子程序、自动运行子程序、堆叠方式处理子程序、故障报警子程序、系统复位及数量清零等子程序组成，如图 3 所示。

SIEMENS SIMODRIVE 6SN1145-1BB00-0EA1

SIEMENS SINUMERIK 6FC5203-0AF01-0AA0 Membrane Keypad

SIEMENS Moore 15945-11-5 BBF Board

Allen-Bradley 2711-K9A1Series C MINT

ABB DRIVE MODULE DSQC546A FOR S4C+ IRB6600/7600 3HAB8101-18/09C TESTED

ACCURAY 125318-001 USPP 125318001

6SN1123-1AA00-0DA1 SIEMENS DRIVES REMANUFACTURED

700 HP TOSHIBA 3PH 4 POLE 1785 RPM INDUCTION MOTOR

PERCEPTRON 912-0021 USPP 9120021

ALLEN BRADLEY 1775-SR5 NSPP 1775SR5

ALLEN BRADLEY 1336S-C010-AA-EN4-HA1-L6 USPP 1336SC010AAEN4HA

GENERAL ELECTRIC DS3800HSQD1G1D USPP DS3800HSQD1G1D

TEXAS INSTRUMENTS PLC 530-1102 NSFP 5301102

STI MS4460X NSPP MS4460X

DYNACORP 307141-28 NSFP 30714128

Siemens 6ES5 955-3LF42 6ES59553LF42

SIEMENS 6ES5 102-8MA02 6ES51028MA02

SIEMENS 6ES5-777-0BC00/6ES5777-0BC00 BUS TERMINAL XLNT

Siemens 6ES5 700-2LA11 /6ES5700-2LA11 7-SLOT RACK W/TERMINATOR XLNT

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Siemens LOGO! 230RC 6ED1 052-1FB00-0BA5 6ED10521FB000BA5

ROBOTRON 503-1-0324-17 USPP 5031032417

Telemecanique TSXDST2472

SIEMENS TI PLC 6MT33 LOGIC INTERFACE MODULE I/O S7 S5

Wago 750-460 4-CHANNEL ANALOG INPUT MODULE

Siemens 7SJ6415-5EB21-1FE0/EE

Modicon AS-S902-111

Schneider Modicon DAP216N AS-BDAP-216N INPUT MODULE 65

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PHOENIX MCR-C-UI/UI-DCI COMMUNICATION INTERFACE MODULE

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Allen Bradley Solid State Timer Relay 700-RTC00000U1 WARRANTY

ABB MEM86-192K + 192KRM

ZINSCO 3034215HM 300 kVa 480 240 60HZ 3P transformer

(V7) 1 GENERAL ELECTRIC 16L0076WH3 CAPACITOR V7

MODICON 140-CPU-434-12 USPP 140CPU43412

ALLEN BRADLEY 1392-A040-RA-MC USPP 1392A040RAMC

GENERAL ELECTRIC DS3815PMMA1F1B USPP DS3815PMMA1F1B

FOXBORO 220S-2F6 USPP 220S2F6

SIEMENS 6ES7-647-2CE10-1CX1 NSFP 6ES76472CE101CX1

SCHRADER BELLOWS 008-4934 NSPP 0084934

WESTINGHOUSE A201K4CA-J1 USPP A201K4CAJ1

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SIEMENS 6ES5-454-7LA11 MODULE 6ES54547LA11

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Siemens S5 Memory SubModule 6ES5 372-0AA61 NIB

Siemens Controller RDE10.1 NIB

Shuttle X50V3 15.6" Atom D2700 GMA3650 DDR3-1600 Gigabit All-In-One System

Square D 8030 HOM-222

Ser.A

WE SHIP SAME WS-CAC-3000W CISCO CAT. 6500 SER. 3000W AC POWER SUPPLY

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Siemens TP177 6AV6 640-0CA11-0AX1 Touch Glass + Film

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Schneider Modicon AS-B802-008 USPP ASB802008

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Schneider Modicon AS-J812-000

Schneider Modicon AS-B872-100 Analog Current Output Module H11 817

SchneiderTSXDSY16T2Premium24VDCSourceOutputModule

SIEMENS 6ES7-138-4FA04-0AB0 6ES71384FA040AB0 DIGITAL INPUT MODULE

Schneider 140CPU43412U 140 CPU 434 12U TSX Quantum Processor 2xMB 1xMB

Siemens HMI 6AV6 644-0BA01-2AX1 NIB 6AV66440BA012AX1

SIEMENS Sinumerik 6FX1126-8BA00 Control Card Interface

SIEMENS 6SE7090-0XX84-0AK0 CB1 MASTER DRIVE COMMUNICATION MODULE 63023

SIEMENS 6SN1-123-1AB00-0HA1 NSFP 6SN11231AB000HA1

SIEMENS 6SN1123-1AA00-0BA1 6SN11231AA000BA1 Simodrive

SIEMENS 6FC5-203-0AC00-1AA0/6FC5203-0AC00-1AA0 NIB

AllenBradleyPanelviewPlusLogicModule2711P-RP8D/A2711PRP8D

Allen-Bradley - 1794-IE8

ABB DCS 500,INDUSTRIETECHNIK AG DCS501-0350-51-21P2100

ADEPT TECHNOLOGY 1033000500 MODULE VJI ROBOT CONTROLLER

(6) MKS 1559A-27301 1559A02821LS1BV MASS FLOW CONTROLLER Range 20 SLM-200 SLM

INDRAMAT MDD-112D-N-030-N2M-130PB2 NSPP MDD112DN030N2M13

VIBRO METER CMC16 USPP CMC16

FANUC A06B-6057-H007 USPP A06B6057H007

DYNAMATIC 15-580-10 USPP 1558010

RELIANCE ELECTRIC 57C-440A USPP 57C440A

NEMATRON CORP ICC-5000-PC1 USPP ICC5000PC1

MODICON AS-516P-002 USPP AS516P002

Siemens 6ES5 417-7AA21 6ES54177AA21

Siemens 6ES5-864-0MA04 NSFP 6ES58640MA04

SIEMENS 6ES5-377-0AB41 USPP 6ES53770AB41

Siemens 6ES5 422-8MA11 16Point Input Module WOW

Siemens S5 6ES5 095-8MA03 6ES50958MA03

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SIEMENS VS710 Vision Sensor 6GF1710-2AA

Siemens 6SN1118-1NH01-0AA0

Mitel Fiber Interface Module FIM 9400-300-301-NA

WS-X6708-10G-3C Cisco 8-Port 10 Gigabit EN Module with DFC3C module 8 ports

Siemens 6ES7 332-5HD01-0AB0 6ES73325HD010AB0 NIB

SIEMENS PLC EEPROM 6ES5 374-0AB11 6ES53740AB11

Reliance 0-55304

Schneider Modicon AC POWER CONVERTER MODEL AS-P120-000

Schneider Modicon AS-B233-501 USPP ASB233501

Schneider Modicon AS-P890-300 NSPP ASP890300

Schneider Modicon AS-B810-008-11 Slot Good Condition

Schneider Modicon AS-B373 Analog Input Module WOW

MODICON OUTPUT MODULE B243-110 NICE

SIEMENS SIMATIC 6ES5434-4UA11 INPUT MODULE 32 POINT

Siemens 6ES7 133-0BH10-0XB0 193-0CA30-0XA0 ET200B S5/S7

Siemens Simatic 505-4616 24/110 VAC Output Module

SIEMENS 6DD1661-0AB0 COMMUNICATION MODULE

SIEMENS SINUMERIK 6FC3551-1AC-Z 6FX1151-1BD00 6FX1138-5BB04 6FX1128-1BA00 COMPLETE SET

SIEMENS 6SN1-111-0AA00-0BA1 USPP 6SN11110AA000BA1

SIEMENS Simodrive 6SC6100-0NA21

SIEMENS 802S 6FC5500-0AA00-1AA0 Membrane Keypad 6FC5 500-0AA00-1AA0

Advantech AIMB-742VE Main Board AIMB-742 Rev.A2 FreShip

ALLEN-BRADLEY 1771-OWNA CONTACT OUTPUT MODULE 1771-0WNA

ABB ACS550-U1-038A-4 ACS550U1038A4

ACTUS POWER pfb-10 supply pfb10 nikki denso

6ES7431-7KF00-0AB0 Brand , Factory Sealed,

900' 350 MCM 350MCM slippery rock Aluminum URD wire 600 volt cable

SQUARE D CF2308G10STM NSPP CF2308G10STM

CAMCO LS14X80 USPP LS14X80

BARBER COLMAN 80BE-00036-201-V-00 USPP 80BE00036201V00

MODICON MM-PMMP-000 USPP MMPMMP000

LANDIS & GYR 549-610 NSPP 549610

DELTAV 12P1442X032 NSFP 12P1442X032

Siemens 6ES5 095-8MD02 6ES50958MD02

Siemens 6ES5-464-8MB11 NSFP 6ES54648MB11

SIEMENS 6ES5 941-7UA12 CPU

SIEMENS S5 6ES5 IP243 243 1AA12 with 491 0LB11

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SIEMENS SIMOREG 6RA23 C98043-A1663-L41-08

Siemens 6ES5256-3AA21

HP/Agilent 81533B Interface module for 8153A

XpressKIT Interface and Bypass Modules from Directed Electronics PLJX

SIEMENS 6ES5-240-1AA11 6ES52401AA11

Siemens MOBIC T8 6GK1611-0TA01-0AV0 Display Panel

Omron CJ1W-SRM21

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Schneider Modicon AS-212P-220 NSPP AS212P220

Schneider Modicon AS-J830-001 MODULE INTERFACE 884/800 ASCII

Schneider Modicon AS-506P-F12 CNC Memory Board Rev C23 (UVG)

Schneider Modicon DEP218/AS-BDEP-218

Schneider Modicon /Schneider AS-B865-001/ASB865001 NICE

SIMATIC S7 Analog Input ModuleTC 6ES7 331-7PF10-0AB0

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Siemens 505-4808 Output Module

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Datascope Mindray Comm Module Communication Module 0998-00-0178-05 Passport 2 XG

SIEMENS Simodrive Drive 6SC6500 6SC6 500 6SC6

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Advantech AIMB-742VE Main Board

ALLEN-BRADLEY 700-P800A-1 RELAY 8NO 120VAC 10AMP XLNT

ABB 3BSE042235R1 PP845, , 3BSE042235R1,

ACCURAY 067452-003 USPP 067452003

A06B-6079-H291 A06B6079H291 FANUC SERVO AMPLIFIER 1 PCS

800MHz Oscilloscope 2CH 5GSa/s 128M Memory Depth 8.4'' TFTLCD 800x600 USB 5082C

SIEMENS 6DD1-670-0AF0 USPP 6DD16700AF0

ALLEN BRADLEY SA3100-B030-AN-L6R USPP SA3100B030ANL6R

ALLEN BRADLEY 6181-AFBCBCZZZ USPP 6181AFBCBCZZZ

KODAK 1350503 NSFP 1350503

GIDDINGS & LEWIS 401-34438-20 NSFP 4013443820

YOKOGAWA CR122-2/H1/W2 NSFP CR1222H1W2

ORMEC SAC-D08M/A USPP SACD08MA

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SIEMENS 6ES5 435-7LA11 6ES54357LA11

SIEMENS S5 6ES5 752-0AA12 6ES5752-0AA12 6ES57520AA12

Siemens Interface Module 6ES5 305-7LA11 38062

Siemens 6ES7 223-1PH20-0XA0 6ES7223-1PH20-0XA0

Siemens OP37 6AV3637-1ML00-0FX0 Membrane Keypad ping Worldwide

QUANTITY OF 10 NETERION X3100 10GBPS ETHERNET NETWORK ADAPTER

Genuine Cisco WIC-1ADSL Interface Module For 1721 1760 2600 2600XM 2691

TEXAS INSTRUMENTS TI 500-5038 NETWORK INTERFACE MODULE

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Siemens EPROM 6ES5375-0LA21 6ES5 375-0LA21

Modicon PC-A984-130

Schneider Modicon Groupe AS-BDEP-210 ASBDEP210

Schneider Modicon AS-BDEP-220 BRAND Guaranteed Discreet Input ASBDEP220

Schneider Modicon AS-C921-000 NSFP ASC921000

Schneider Modicon AS-M84A-002

Schneider Modicon AS-B840-108 ASB840108

Schneider Modicon MEMORY CPU AS-S480-207 S480-200 ASS480207

Schneider Telemecanique XBT NU400 XBTNU400

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

PROTECH PIRAMID SDI-77XL PASSIVE INFRARED DETECTOR

SIEMENS 6ES5 470-8MC12 ANALOG OUTPUT MODULE

SIEMENS 6DD1-684-0DC0/6DD1684-0DC0/465 684 9032.00 PSV/ATV CABLE NIB

IBM 11F4814 Communication Controller Module Modem

SIEMENS SIMODRIVE 6SN1145-1BA01-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 #2ZH

SIEMENS SINUMERIK 820 T 6FC3261-1AC-Z CONTROL PANEL 5703029301.00 TESTED

SIEMENS MOORE PRODUCT VALVE 73N-FR B/M 10637-/14MC

Allen-Bradley PanelView 900 2711-K9C3 Series C Revision B WARRANTY

54645D Mixed Signal Oscilloscope, all Accessories, Calibrated, 30

ABB Soft Starter PST300-600-70

A06B-0153-B075#7008 FANUC SERVO MOTORS REMANUFACTURED

705330-325

RELIANCE ELECTRIC 0-52842 NSFP 052842

ALLEN BRADLEY 1785-L20E/E NSFP 1785L20EE

ALLEN BRADLEY 1336Z-SB017-N NSFP 1336ZSB017N

GENERAL ELECTRIC DS3800NHVE1C1C USPP DS3800NHVE1C1C

THOMSON INDUSTRIES 2DB16-JOBGX84 NSFP 2DB16JOBGX84

SUN MICROSYSTEMS T9840C USPP T9840C

FANUC A06B-0227-B005 USPP A06B0227B005

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SIEMENS 6ES5 308-3UA12 6ES5308-3UA12 Serial Interface EPROM 16kB CASING

SIEMENS 6ES5-911-0AA42 USPP 6ES59110AA42

Siemens 6ES5 701-1LA12 6ES5 701-1LA12S5 ER 701-1 9-Slot Expansion Rack

SIEMENS 6ED1 052-1CC00-0BA4 ping

SIEMENS LOGO! 6ED1 052-1HA00-0BA0 24R

RME HAMMERFALL HDSP 9632 AUDIO INTERFACE SOUND CARD

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SIMATIC S7 6ES71511BA020AB0 6ES7 151-1BA02-0AB0

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Schneider Modicon Automation Power Supply AS-P120-000 2869