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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。

ALLEN BRADLEY 1397-B010R-HA1 USPP 1397B010RHA1

BAUMULLER BUM62F-75/975-54-M-041 USPP BUM62F7597554M04

AVTRON A19359-1 NSPP A193591

MODICON AS-J212-001 USPP ASJ212001

ITE SIEMENS HNFC365J NSFP HNFC365J

CET MPC4 USPP MPC4

Siemens 1P 6ES5-095-8MC02 6ES50958MC02 Central Unit System

Siemens 6ES5-456-4UB11 USPP 6ES54564UB11

SIEMENS 6ES5 752-0AA53 -FS- 6ES57520AA53

SIEMENS S5 6ES5 464-8MC11 6ES54648MC11

Siemens S5-135U 928B CPU 6ES5 928-3UB11

SIEMENS 6ES7215-2BD00-0XB0 CPU 215-2 PROFIBUS DP

SIEMENS SIMATIC CONNECTOR 6ES7392-1AM00-0AA0 NIB

Siemens 505-7202

HP 81534A Return Loss Module with 81000FI Interface

Works on 2000 different vehicles No key required

SIEMENS 6ES5 393-0UA15 OP393-III

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Omron C200H-LK201

Schneider Modicon AS-H819-107 PLC

Schneider Modicon Discrete Input Relay AS-BDAP-216

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AC SERVO DRIVER PANASONIC MSD011A1X ping

Allen-Bradley 800T-B6 30.5mm Type 4/13 Push Button Red

ABB 1500 KVA 22860 GRD Y / 13200/480Y/277 3 PH Padmount Transformer F3IE14CPL9

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A06B-6059-H218 FANUC DRIVES REMANUFACTURED

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ALLEN BRADLEY 803-PL6 NSFP 803PL6

ALLEN BRADLEY 512-EAB-1-27 NSPP 512EAB127

ISSC 396-115 USPP 396115

GENERAL ELECTRIC DS3800HSHA NSPP DS3800HSHA

YASKAWA ELECTRIC CACR-PR03BC3AM NSFP CACRPR03BC3AM

MITSUBISHI A54MA22B FNFP A54MA22B

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Texas Instruments 5TI-3201

Tellabs Titan 825345 T3 Interface Module T3D1CCT2AA

TSXDMZ28DT TESTED Modicon Micro Combination Module TSX-DMZ-28DT

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A06B-0148-B175#7075 FANUC SERVO MOTORS REMANUFACTURED

7 MKS 127AA-00001E 1Torr Baratron Pressure Transducer

PERCEPTRON 911-0007 USPP 9110007

ALLEN BRADLEY 1774-LP3 USPP 1774LP3

ALLEN BRADLEY 1336S-B015-AA-EN4 USPP 1336SB015AAEN4

GENERAL ELECTRIC DS3800HAIA1E1D USPP DS3800HAIA1E1D

TELEMECANIQUE LC1-F5004 NSFP LC1F5004

SQUARE D ME36200LS USPP ME36200LS

CUTLER HAMMER CE15NN3T1 NSFP CE15NN3T1

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SIEMENS 6ES5-752-0AA53 NSFP 6ES57520AA53

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Roland VG-99 V-Guitar Multi Effects Processor System with GK-3 Pickup

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Modicon AS-P830-000

Schneider Modicon DISCRETE INPUT MODULE DEP 218/AS-BDEP-218 DEP218/AS-BDEP-218

Schneider Modicon ASB231 ASB231001 Input Module AS-B231-001

Schneider Modicon AS-B875-012 ANALOG INPUT

Schneider Modicon AS-B875-102 I/O Analog High Speed 8CH

Schneider Modicon GOULD C921 COMMUNICATION PROCESSOR AS-C921-101

Schneider Modicon AS-M380-006 Memory Module

SCHNEIDER AUTOMATION OUTPUT MODULE DAP 216N/AS-BDAP-216N DAP216NASBDAP216N

Siemens 505-4332 Input Module 14-30VDC

RELIANCE ELECTRIC B/M-60031-4 USPP BM600314

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ALLENBRADLEY1794-OF4IOUTPUTMODULESERIESA

Allen Bradley Terminal Board 9101-1779 Amphenol Connector /Sealed

ABB K-Don -800M Circuit Breaker Manually Operated 1200 Amp Fuses

Zener SmartStart TC23000 208-430VAC 3 Phase F.L.C Motor Starter

(SIEMENS)IPC(Industrial Personal Computer)6ES7 643-4DC00-0CA0 for industry use

MITSUBISHI FR-Z240-5.5K-UL NSFP FRZ24055KUL

ALLEN BRADLEY 1336VT-B060-EOS-FA2-L3 NSFP 1336VTB060EOSFA2

GENERAL ELECTRIC 803612-RE USPP 803612RE

FORNEY 32747406 USPP 32747406

SIEMENS 6ES5-928-3UA12 USPP 6ES59283UA12

REXROTH PPCR022N-N-NN-NN-NN-FW USPP PPCR022NNNNNNNNF

TRICONEX 2661 USPP 2661

Siemens 6ES5 525-3UA21 6ES55253UA21

Siemens ANALOG INPUT MODULE 6ES5 464-8MA21 IN BOX

SIEMENS 6ES5453-4UA12 6ES5 453-4UA12S5 453-4 Digital Output Module

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Siemens Card 6ES7793-2AA00-0AA0 6ES7 793-2AA00-0AA0

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Square D 8030 DRK-300

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WIFI H.264 SONY CCD 27X PTZ IP Security Camera Wireless

SIEMENS 6ES7-972-0AA01-0XA0 6ES7972-0AA01-0XA0 FreeShip

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Schneider Modicon ASE908016 BRANDExecutive Module AS-E908-016

Schneider Modicon AS-B573-015 ANALOG INPUT MODULE ASB573015

Schneider Modicon Controller AS-P892-000

Schneider Modicon AS-HBOX-201 USPP ASHBOX201

Schneider Modicon AS-B864

Modicon 140DRA84000 16 Point Relay Output Module

SIEMENS 6ES7-331-7KF02-0AB0 INPUT MODULE 8POINT ANALOG S7-300 SM331

SCHNEIDER MODICON 140CPU43412A 140 CPU 434 12A TSX Quantum

SIEMENS LD1E060 NSPP LD1E060

SIEMENS Sinumerik 6FX1120-3BA01 PC Board E Stand D & 00

Siemens REMOTE COMMUNICATIONS MODULE 560-2126-R

SIEMENS 6SN1123-1AA00-0HA1 USPP 6SN11231AA000HA1

SIEMENS 6SN1123-1AA00-0HA1 SIMODRIVE MODULE 6SN1118-0AA11-0AA1

SIEMENS 6FC5210-0DA20-1AA0 6FC5 210-0DA20-1AA0 SINUMERIK 840D MMC 103 Version B

AllenBradleySLC500OutputModule1746-OA16SeriesD

Allen-Bradley - 2711P-T7C4D1 - NO BOX

ABB CIRCUIT BREAKER SACE E3-N-A 2000, 100% REAR TERMINALS 3 POLES

ADEPT TECH 90402-40013 USPP 9040240013

(4715) Baldor AC Inverter Drive ID15H215W 230VAC 15H (4715)

INDRAMAT MAC112B-0-LD4-C/130-A-0/W1520LV/S005 NSPP MAC112B0LD4C130A

TOSHIBA VT130G7U-4400B NSFP VT130G7U4400B

FANUC A06B-6044-H312 NSFP A06B6044H312

DAYKIN APFS-15-A156 NSFP APFS15A156

RELIANCE ELECTRIC 45C-271 NSPP 45C271

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Reliance 0-52808

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ALLEN-BRADLEY 1778-OYC CONTACT OUTPUT MODULE BULLETIN

ABB ACS 600 INVERTER UNIT AC DRIVE 64184652 135A AMP ACN634012050000 71271

Actus Power AC Servo Controller NPSA-103MU-1ECS USPP NPSA103MU1ECS Pak 3PH 220V

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KENNEDY 9218 USPP 9218

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HP Agilent M1082-66501 SDN-IF Interface Card Module

xantech 797-22Universal Interface Module F-type interface cable McIntosh

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Omron C500-BC081

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Schneider Modicon ANALOG OUTPUT MODULE DAU 202 / AS -BDAU -202

Schneider Modicon AS-J475-000 USPP ASJ475000

Schneider Modicon ADAPTER CONNECTOR AS-MBKT-085 (BIN 63)

Schneider Modicon DAP216N/AS-BDAP-216N

Schneider Modicon /AEG/Schneider AS-BDEP-254/ASBDEP254 Input

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