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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 SIMATIC S7 CP341 RS232 COMMUNICATIONS MODULE 6ES7 341 6ES7341-1AH01-0AE0

Honeywell Communication Module 620-0044 13832

SIEMENS Simodrive 6SN1123-1AA00-0AA1 6SN11231AA000AA1

SIEMENS SINUMERIK 840D/DE NCU 572.4 6FC5357-0BB23-0AE0 NIB

SIEMENS Control Rack 6FC3741-0FB Z_ 6FC _6FX1120-1CA01

AllenBradleyPanelview550BacklightBulbReplacement

ALLEN-BRADLEY DATALINER OPERATOR INTERFACE CAT2706-D21J8

A-B NIPPONDENSO 8500-A3D-L1B AC Servo Motor [PZ4]

AC Motor Invertor - 30 HP - 480 Volt - Three Phase Input

A06B-0583-B072#7008 FANUC SERVO MOTORS REMANUFACTURED

750' Notre Dame 1/0 1/0 1/0 2 Aluminum URD Direct Burial URD XLP USE 600V

RELIANCE ELECTRIC GV3000E-AC008-AA-DBU NSFP GV3000EAC008AADB

ALLEN BRADLEY 5250-LP1 USPP 5250LP1

ALLEN BRADLEY 2094-BC07-M05S USPP 2094BC07M05S

INDRAMAT KDS1.1-150-300-W1 USPP KDS11150300W1

YASKAWA ELECTRIC CACR-TM333Z1SPY8 NSFP CACRTM333Z1SPY8

WESTINGHOUSE 210P085H01-1 USPP 210P085H011

HYDE PARK SP106 USPP SP106

Siemens 6ES5-244-3AA22 USPP 6ES52443AA22

SIEMENS 6ES5 376-1AA31 -- 6ES53761AA31

SIEMENS Interface Module 6ES5 752-0AA43 WITH PAPERWORK

Siemens Analog Input Module 6ES5 460-7LA12

Siemens 6ES7 131-0BL00-0XB0 6ES7131-0BL00-0XB0 ET200B

SIEMENS MP370 12.1" MP370-12 6ES7542-0DA10-0AX0 Touch Screen Display Glass

Reliance Automate 30 45C305A 45C305 Processor

Texas Instruments 505-4508

STATIC CONTROLS 920-M-2-V 4.3 INTERFACE DISPLAY MODULE

UBR7246VXR CISCO UBR 7246 4MC 2PA SLOTS 1YR - ASK 4 QTY

Siemens Control Board C98043-A1304-L Simodrive

Modicon AS-WBXT-201

Schneider Modicon NIBAutomation Output Module DAP 210/AS-BDAP-210

Schneider Modicon AEG/GOULD/MODICON/ AS-E381-902 EXECUTIVE CARTRIDGE XLNT

Schneider Modicon AS-BDEP-112 NSFP ASBDEP112

Schneider Modicon ASBDAP216 Compact Out Module AS-BDAP-216

Schneider Modicon -AS-500P-000

Schneider Modicon DAP 218 DAP218 Output Module AS B075-000 94V

Schneider Proximity Sensor XS530B1DAL2 NIB DC12-48V

SCHNEIDER MODICON TSX QUANTUM 115V AC INPUT MODULE 140 DAI 540 00

QX41 Mitsubishi PLC 32 Point DC Input

SIEMENS 6ES5456-4UA12 Digital Output Module NIB-FS

SIEMENS Sinumerik 802S 802C 802 5.7 inch LCD screen display

Mitsubishi AJ71UC24 Melsec Communication Module Link

SIEMENS SIMODRIVE 6SN1118-0NH11-0AA0

SIEMENS SINUMERIK CNC KEY BOARD 6FC5203-0AC00-0AA2

SIEMENS /MOORE QLCAMAAN QUADLOG CAM MODULE 16404-1/1

ALLEN-BRADLEY VERSAVIEW CE 1500H 6182H-15BRH4D 6189-RPRH LOGIC MODULE

Allen Bradley SLC 500 1746-OB16 Ser D Output Module 10-50VDC

ABB ROBOTIC DRIVE 3HAB-5845-1/2-DSQC334

A06B-0147-B075#0008 FANUC SERVO MOTORS REMANUFACTURED

01KA509430 RELIANCE DC MOTORS

NACHI AUXL-111 USPP AUXL111

ALLEN BRADLEY 1756-L53 NSPP 1756L53

ALLEN BRADLEY 1336-B015-EAE-S1 USPP 1336B015EAES1

GENERAL ELECTRIC 531X122PCNACG1 NSFP 531X122PCNACG1

SQUARE D S164N NSPP S164N

SIEMENS 6SE7021-0EA61 USPP 6SE70210EA61

BALDOR GHF2030BH USPP GHF2030BH

Siemens 6ES5 944-7UB21 6ES59447UB21

Siemens Simatic S5 6ES5 928-3UB11 CPU 6ES5-928-3UB11

SIEMENS 6ES5-701-1LA12/6ES5701-1LA12 9-SLOT EXPANSION RACK NIB

Siemens 6ES5 482-8MA13 I/O MODULE 6ES54828MA13

Siemens 6AV3607-1JC30-0AX1 OP7 in Box ping Worldwide

Siemens Inverter 6SE9521-0DC40

Samsung NP400B2B-A01US Notebook laptop 2.50 GHz 12.5" Screen Size 1.3 MP Cam

Syscon C400FJA3

SIEMENS Interface Module 6ES5310-3AB11 NIB Opened Compare @ 480.00

QUANTITY AVAILABLE SERIES A

Siemens 6SE7031-7HG84-1JA1

Siemens VAS5052A Touchscreen Glass

Schneider Modicon AS-BDAP-216N TSX Compact Current Source

Schneider Modicon ASB875101 Refurbished TESTED Analog INPUT Module AS-B875-101

Schneider Modicon AS-B846-002 MODULE ASB846002

Schneider Modicon 984 series of AS-B808-016 good in condition

Schneider Modicon Battery CELLS AS-5284-001

Schneider Modicon AS-H827-209 984 Series 11 Slot Rack ASH827209

Schneider Modicon PanelMate Plus 1000 MM-PM1030SC 92-01686-00

SIEMENS 6ES5 788-8MA11 Input Output Module

RME HDSPE PCI EXPRESS CARD INTERFACE MULTIFACE DIGI

siemens board 6FX1124-6AD02

SIEMENS Sinumerik DM 16 E-MODUL 6FC5111-0CA01-0AA0

Reliance Electric 57C404B Network Communications Module

SIEMENS CONTROLLER CARD 6SN1118-0NH01-0AA1

SIEMENS 6SL3000-0DE23-6AA0 6SL3 000-0DE23-6AA0 Simodrive HFD Line Reactor QT

SIEMENS 6FC5-110-0BA01-1AA0 NSPP 6FC51100BA011AA0

Allen-Bradley2711-NM11MemoryCard256KBLotof2

ALLEN BRADLEY VersaView 1200P TOUCH SCREEN OPERATOR INTERFACE 6181P-12TSXPH

ABB IMMFP12 PROCESSOR IN A

Advanced Energy MDX Pinnacle 8kW DC Magnetron Power Supply AE 3152352-122B

(N3-1) 1 EATON ECN2414CAE CONTROL N3-1

MEASUREX 084736-00 USPP 08473600

ALLEN BRADLEY 1336-B050-EAG-S1 USPP 1336B050EAGS1

GE FANUC IC646MBP001 FNFP IC646MBP001

FANUC A16B-1000-0140 USPP A16B10000140

SIEMENS 6AV7-614-0AB12-0BJ0 USPP 6AV76140AB120BJ0

RELIANCE ELECTRIC 2GU51010 USPP 2GU51010

SIEMENS 6ES7-651-5AF17-0YH5 NSFP 6ES76515AF170YH5

Siemens 6ES5 470-4UC12 6ES54704UC12

Siemens 6ES5-946-3UA23 USPP 6ES59463UA23

SIEMENS 6ES5-440-8MA21 NSFP 6ES54408MA21

Siemens 6ES5 816-1BB11 TRANSMISSION LOG MODULE

Siemens S5 6ES5 947-3UA11 6ES59473UA11

SIEMENS C98043-A1200-L in Box

Siemens 6ES5 482-7LA11 Digital Output Module

Square D 8030 CBP-104

Omega OMEGACARLINK CARLINK Add-On Smartphone Interface Module w/ Remote Start

WS-C3550-24-DC-SMI CISCO 3550 SWITCH 24-10/100 2 GBIC PORTSDC-PWRD: SMI

Siemens 6ES7314-6CG03-0AB0

Siemens SIMODRIVE 6SN1130-1AA11-0EA0

Reliance SP500

Schneider Modicon ASP371001 Gould Program Pack AS-P371-100

Schneider Modicon AS-B546-000 USPP ASB546000

Schneider Modicon AS-W600-003 NSPP ASW600003

Schneider Modicon AS-BDEP-210 ASBDEP210 DEP 210 AC Input NIB

Schneider Modicon AS-B825-016 INPUT TRUE HIGH MODULE

MODICON ANALOG OUTPUT MODULE DAU 202 / AS -BDAU -202

SIEMENS ET 200X PLC INPUT OUTPUT MODULES 1BF11 1BF30 1DA00

Sharp JW50H JW-50CUH JW50CUH Control Module

Siemens Operator Interface Model 4700-DRMC3-11HN

SIEMENS SINUMERIK 6FC 3671-0FB-Z CONTROL RACK

TEKTRONIX COMMUNICATION DC POWER MODULE VSS75

SIEMENS 6SN1118-0NJ01-0AA1 SIMODRIVE 611 U HR 1-AXIS CONTROL LOOP BLOCK RESOLV

SIEMENS POWER SUPPLY SIMODRIVE 6SN1145-1BA01-0BA1

SIEMENS 6FC5-250-5PX10-3AH0 USPP 6FC52505PX103AH0

Advantech Remote Contact/Digital Input ADAM-4053

ALLEN-BRADLEY 1746-0AP12 SER. C REMOTE OUTPUT MODULE ""

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88143

ADEPT TECH 10332-00500 USPP 1033200500

(000 nolot) Allen Bradley Motor 31HP (Kw) 37.1V 1600 RPM 8720SM-030Z4JAS2

INDRAMAT DDC01.2.N050C-RL01-01-FW USPP DDC012N050CRL010

TELEMECANIQUE ATV-66D64N4U USPP ATV66D64N4U

EEC AEG THYRO-3M-500-495-HF USPP THYRO3M500495HF

CUTLER HAMMER 92-00988-02 USPP 920098802

PPT VISION 661-0306 USPP 6610306

MODICON AS-584A-039 USPP AS584A039

INDRAMAT CLC-P01.1 USPP CLCP011

Siemens 6ES5 312-5CA12 -FS- 6ES53125CA12

Siemens 6ES5-526-3LG11 USPP 6ES55263LG11

SIEMENS 6ES5-374-0BA11 NSPP 6ES53740BA11

Siemens 6ES5 308-3UA12 6ES53083UA12 INTERFACE S5-115

Siemens 6ES5-524-3UA13 6ES5524-3UA13 N90

SIEMENS 6GK7443-5FX01-0XE

SIEMENS TP270 6AV6 545-0CC10-0AX0 Touch Panel Excellent Condition

Siemens 6ES5941-7UA12

LIKE CONDITION GUARANTEED TO WORK OR MONEY BACK

Yaskawa 87350-23001 PLC Module 8735023001 XLNT

Siemens 6ES7 223-1PH00-0XA0 6ES7223-1PH00-0XA0 FreeShip

Siemens OP37 6AV3637-1ML00-0CX0 Membrane Keypad ping Worldwide

Reliance 0-51377-35

Schneider Modicon AS-B805-000/ASB805000 Input

Schneider Modicon AS-9000-790 NSFP AS9000790

Schneider Modicon AS-P371-001 USPP ASP371001

Schneider Modicon AS-B350-001 OUTPUT MOD. B350001 ASB350001

Schneider Modicon AS-8535-000 HIGH-/LOW-DENSITY CONNECTOR NIB

MODICON TELEMECANIQUE MAGELIS OPERATOR INTERFACE TXB TF024510E PARTS/REPAIR

SIEMENS Simatic S7 6ES7 421-1BL01-0AA0 Digital Input Module

Siemens 6ES7 334-0CE01-0AA0 -- 6ES73340CE010AA0

SIEMENS SIMATIC PANEL 6AV6 5A5-0BA15-2AX0 EXCELLENT SHAPE 24 V DC RS232 COM

Siemens 9300 9300DC-100-ZZZZA Power Meter Display ION Profibus Access

SIEMENS SINUMERIK MMC 102 6FC5210-0DA20-0AA1 NE

SIEMENS OPTION PROFIBUS DP2 6SN1114-0NB00-0A

SIEMENS SIMODRIVE 6SN1123-1AA00-0DA2

SIEMENS E Stand 1P 6FC5111-0CA73-0AA1 6FC50000CA730AA1

Advantech POS-7671

ALLEN-BRADLEY 2711E-K10C6 PANELVIEW 1000E OPERATOR INTERFACE

ABB 6400R M2000 robot with S4C+ control system

Acterna InfiniPort Test System

6ES5-244-3AB31 SIEMENS TEMPERATURE CONTROL MODULE S5 IP244 F/115/135/155U

8520-RI0M1 ALLEN BRADLEY ELECTRONIC CIRCUIT BOARD

SIEMENS 6SE6-440-2AD33-0EA1 USPP 6SE64402AD330EA1

BAILEY CONTROLS IMMFP-02 NSFP IMMFP02

ASEA BROWN BOVERI YPQ108A USPP YPQ108A

MODICON AM-0984-AT4 USPP AM0984AT4

INDRAMAT MDD093B-N-030-N2L-110PB0 USPP MDD093BN030N2L11

ASEA BROWN BOVERI QHMM101 USPP QHMM101

TYLAN GENERAL FM-3926V NSFP FM3926V

Siemens 6ES5-450-6AA12 USPP 6ES54506AA12

SIEMENS 6ES5 700-1LA11 6ES57001LA11

SIEMENS S5 6ES5 375-1LA41 6ES53751LA41 Memory

Siemens S5 6ES5246-4UA21 6ES5 246-4UA21 6ES52464UA21

Siemens 6ES7 972-0BB12-0XA0 6ES7972-0BB12-0XA0 ping Worldwide

Siemens S7 PLC to Operator Interface TD200-PLC Cable

Siemens 3RW3454-0DC34

Honeywell PLC 620-0042 Communications Interface Module

Waters Millipore HPLC System Interface Detector Module

Siemens 6DS1844-8DA

Siemens LOGO! 6ED1 052-1CC01-0BA6 NIB

Omron 3G2A6-LK014

Schneider Modicon AS-J892-101 SURPLUS ASJ892101

Schneider Modicon PROGRAMMABLE CONTROLLER AS-584L-231

Schneider Modicon AS-H827-100 NSFP ASH827100

Schneider Modicon LOT of (4) Card Module DEP 216/AS-BDEP-216

Schneider Modicon AS-BDEP-257 I/O MODULE ASBDEP257

Schneider Modicon SCHEIDER POWER SUPPLY AS-P810-000 15A0290-000 70W 115/230V

Telemecanique MODICON TSX Micro TSX3710001

SCHNEIDER Telemecanique Switch XB4 BVB5

Siemens X102 Operator Panel MS 100 H MS100H MS 1OO H MS1OOH MS-100-H

SIEMENS 6AV3688-3ED13-0AX0 PP17-II PUSH BUTTON PANEL

SIEMENS Sinumerik 6FC5203-0AF02-0AA0 PCU 50 Display

GE Communications Control Module IC693CMM311K

SIEMENS SIMODRIVE VPM 120 6SN1113-1AA00-1JA0

SIEMENS SIMODRIVE 6SN1146-1AB00-0BA1SINUMETIK 840D NCU-BOX 6FC52476FC5356 2ST

SIEMENS 07-09KIAAMANTIKEYLESSREMOTEFCC:SY55WY8412 VDOGOOD CONDITION

Allen-Bradley Analog Output Module 1771-OFE2/B

AB,ALLEN-BRADLEY BULLETIN GMC DIGITAL SERVO CONTROR 10KW 1394 ,AXIS 10KW,CK

AC Power AFC-11005A Single Phase In Single Phase Out Power Suppy

A06B-0759-B200#3000 FANUC AC SERVO SPINDLE REMANUFACTURED

75HP 3PH 460V VFD TECO WESTINGHOUSE VARIABLE FREQUENCY DRIVE JNTEBGBB0075AZ

REXROTH 0-608-830-093 USPP 0608830093

ALLEN BRADLEY 6160-PCD4 USPP 6160PCD4

ALLEN BRADLEY 2706-F21J USPP 2706F21J

INDRAMAT MDD093C-N-030-N2M-110PA1 USPP MDD093CN030N2M12

YASKAWA ELECTRIC JANCD-SV02C NSPP JANCDSV02C

WESTINGHOUSE PC-1200-1042 USPP PC12001042

ITE SIEMENS NF355H USPP NF355H

Siemens 6ES5-250-1AA11 USPP 6ES52501AA11

SIEMENS 6ES5 380-7AA11 6ES53807AA11

SIEMENS PLC 6ES5 306-7LA11 Interface

Siemens BUS TERMINAL SINEC L2 RS485 OVR 6GK15000AB

Siemens 6ES7 153-2BA02-0XB0 6ES71532BA020XB0 NIB

Siemens OP17 6AV3617-1JC00-0AX1 in Box

RELEASE SuperMicro X9SRE-F Motherboard FULL MFR

Texas Instruments 505-7002

Sunpak MX-2D Interface Module. 11104

TYAN Tempest i5000PX S5380 Intel Socket 771 Server MOTHERBOARD S5380G2NR