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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 2711-K6C1 NSPP 2711K6C1

ALLEN BRADLEY 1756-M13 NSPP 1756M13

Siemens 6ES5 951-7ND51 6ES59517ND51

SIEMENS 6ES5 451-7LA11 6ES54517LA11

SIEMENS 6ES5-453-4UA11 6ES5453-4UA11

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Siemens 6AV6642-0AA11-0AX0 6AV6 642-0AA11-0AX0 TP177A

SIEMENS OP7 6AV3 607-1JC30-0AX0 Membrane Keypad

Siemens 6ES5100-8MA02 6ES5 100-8MA02 SIMATIC S5-100U CPU100 Controller

Square D 8020 SCP-423

OFFER WIN- Allen-Bradley 1492-IFM20D120 Ser.A Rev.A Interface Module

WS-C3560V2-24TS-SD FREE 1 YEAR CISCO 3560V2 SWITCH

Siemens 6ES7291-8GE20-0XA0 Memory Module

Siemens SIMATIC S7-400 6ES7 412-2XG00-0AB0 CPU 412-2

Reliance 803612-SE

Schneider Modicon ASW808002 Excellent Cable Assembly AS-W808-002

Schneider Modicon AS-B375-001 USPP ASB375001

Schneider Modicon AS-TM84-001 NSFP ASTM84001

Schneider Modicon AS-BDAP-216 DISCRETE OUTPUT MODULE 16X24VDC

Schneider Modicon AS-B824-016 24 VDC OUTPUT TRUE HIGH

MODICON AS-B350-001 OUTPUT MODULE GOULD AEG B350 115 VOLT AC

SIEMENS INPUT MODULE 505-4332 5054332

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

SIEMENS OPERATOR INTERFACE TOUCH PANEL SIMATIC TP27 6AV3 627 6AV3627-1QL01-0AX0

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Telemecanique TSX MPT 10 Telway 7 Communication Module

SIEMENS 6SN1118-0DM23-0AA0 6SN11180DM230AA0 Servo

SIEMENS SIMODRIVE - 6SN-1145-1BA01-0BA1 E/R Module INT 16/21kw

SIEMENS 6FC5-356-0BB11-0AE1 USPP 6FC53560BB110AE1

Advantech PCM7230-CK001

ALLEN-BRADLEY 1746-OB32 32 ch-DC Output Module For Programmable Controller sour

ABB BAILEY SYMPHONY CONTROLS DIGITAL IMASI23 ANALOG INPUT SLAVE MODULE 88109

ADEPT TECH 10330-10150 USPP 1033010150

(000 BACK AL)1 NIB SIEMENS 6SE7031-0EE60 6SE7090-0XE87-3AC0 CONVERTER DRIVE

IMPERIAL 08134600 USPP 08134600

TECRON 7700 USPP 7700

DYNAMATIC 15-503-4003 USPP 155034003

CUTLER HAMMER 1MTBE800R NSFP 1MTBE800R

PEPPERL & FUCHS MVH2000-F15 USPP MVH2000F15

MODICON AS-516P-008 NSPP AS516P008

HONEYWELL 30734558-001 USPP 30734558001

Siemens 6ES5 308-3UC21 6ES53083UC21

Siemens 6ES5-526-3LA11 NSFP 6ES55263LA11

SIEMENS 6ES5-373-0AA41 USPP 6ES53730AA41

Siemens 6ES5 255-1AA11 6ES5255-1AA11 6ES52551AA11

Siemens 6ES5-430-7LA11/6ES54307LA11 NICE

SIEMENS 6GK7343-1CX00-0XE0

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Siemens 6ES5788-8MA11

Latest Bluetooth Module Cradle 2005 to 2008 Mercedes E320 E350 E500 E550 E55 E63

YASKAWA ELECTRIC DISCT-J1040 USPP DISCTJ1040

Siemens 6ES7 223-1BH00-0XA0 6ES7223-1BH00-0XA0 FreeShip

Siemens OP37 6AV3 637-1ML00-0FX0 Membrane Keypad

Reeves SBAI-1001-11

Schneider Modicon AS-B807-032 ASB807032 32 Point 120 VAC Input

Schneider Modicon AS-884A-201 PROCESSOR MODULE AS884A201

Schneider Modicon AS-P180-010 USPP ASP180010

Schneider Modicon AS-B243

Schneider Modicon AS-5540-003 Bus Duct

Modicon TSX Quantum 24-230 VAC Output Module 140DAO84000

SIEMENS SIMATIC S7 SM321 DIGITAL INPUT MODULE PLC 6ES7 321 6ES7321-1BH02-0AA0

TELEMECANIQUE XBTGT2110 Touchscreen Glass

Siemens Simatic Relay Output Module 505-4916A 16 pts

Siemens 9510 9510DC-1156-GZZA NIB Power Meter Display ION Ethernet Access

SIEMENS SINUMERIK I/O MODULE 6FC5611-0CA01-0AA0

SIEMENS 6SN1123-1AA00-0EA0 6SN1 123-1AA00-0EA0 SIMODRIVE 611 160A Ver D

SIEMENS SIMODRIVE 6SN1123-1AA00-0LA1

SIEMENS HMI 6FC5253-6BX10-2AFC PCU 50 566mHZ6FC5210- 00F20-0AA0840D BS003

Advantech PCM-7130 Rev.A1 NIB

ALLEN-BRADLEY 2711-K5A20 PANELVIEW 550 2711K5A20 CLEAN TESTED GOOD COND.

ABB 6008BZ10000C VIDEO MODULE PCB

Acterna ANT-20

6962ED2580A2 Starter CUTLER HAMMER

8520CPUX ALLEN BRADLEY ELECTRONIC CIRCUIT BOARD REMANUFACTURED

SIEMENS 6SE3-221-3DC40 USPP 6SE32213DC40

AVTRON AFS110-4CN0-C USPP AFS1104CN0C

ASEA BROWN BOVERI MSB63800L NSFP MSB63800L

MODICON 140-CPU-534-14 USPP 140CPU53414

INDRAMAT MDD071C-N-030-N2S-095PB0 NSFP MDD071CN030N2S01

ASEA BROWN BOVERI ACH401601632+A0BE0000 USPP ACH401601632A0BE

TITAN CORPORATION MMI-150 USPP MMI150

Siemens 6ES5-441-7LA13/6ES5441-7LA13 OUTPUT MODULE NIB

SIEMENS 6ES5 521-8MA21 6ES5521-8MA21

SIEMENS S5 6ES5 310-3AB13 6ES53013AB13

Siemens S5 6ES5 544-3UA11 6ES5544 6ES55443UA11

Siemens 6ES7 953-8LG20-0AA0 6ES79538LG200AA0 128K MMC in Box ping

Siemens S5 PLC Lithium Battery 6ES5 980-0AA21 NIB

PMA DC 150-CAN inbligent DDC control PLC 16 digital I/O 9407 700 50341

HONEYWELL EXPERIAN TC-CCR013 DUAL REDUNDANT NET INTERFACE MODULE

Wago 750-631 Interface Module 750631

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Siemens LOGO! 230RC 6ED1052-1FB00-0BA6 in box

Omron 3G2A5-PS221E

Schneider Modicon AS-M84A-102 ASM84A102 CPU Processor NIB

Schneider Modicon MEMORY BOARD AS-506P-F12 REV C21 /REPAIRED

Schneider Modicon AS-H819-107 NSPP ASH819107

Schneider Modicon GOULD/ MODULE - AS-B814-001

Schneider Modicon AS-BDEO-216 INPUT MODULE ASBDEO216

Schneider Modicon REMOTE I/O ADAPTOR POWER SUPPLY AS-P890-0005201

Telemecanique Inverter Operator Panel ATV71

Schneider Telemecanique Overload Relay LRD16KN

SIEMENS/TI/CTI 505-2599/2599 32PT AC OUTPUT MODULE XLNT

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SIEMENS Sinumerik 6FC5147 0AA05 0AA0 6FC51470AA050AA0

GE FANUC COMMUNICATION CONTROL MODULE IC693CMM311G IC693CMM311-G

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SIEMENS Bellows Assembly for Moore Valve Positioner 118-190

Allen-Bradley Cat. No. 1771-OGD TTL Output Module

AB PLC PLC-5/V30B 1785-V30B PLC-5-V30B ``NICE``

AC Motor Invertor - 60 HP - 600 Volt - Three Phase Input

A06B-0731-B900#0900 GE FANUC AC SERVO SPINDLE REMANUFACTURED

750’ 8/5 SOOW SO Portable Power Cord Adjustable Water Resistant Outdoor 600V

RELIANCE ELECTRIC SA3000DC070 USPP SA3000DC070

ALLEN BRADLEY 5370-CVIM NSFP 5370CVIM

ALLEN BRADLEY 20BD027A3AYNADC0 NSPP 20BD027A3AYNADC0

INDRAMAT MAC093B-0-JS-2-C/130-B-0/S005 NSFP MAC093B0JS2C130B

YASKAWA ELECTRIC CPCR-AN051B NSPP CPCRAN051B

WESTINGHOUSE 4256A88G04 USPP 4256A88G04

INDUSTRIAL DEVICES SMARTSTEP23 USPP SMARTSTEP23

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SIEMENS 6ES5 377-0AA21 -- 6ES53770AA21

SIEMENS MEMORY MODULE 6ES5 375-1LA61

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Reliance 57401 57401-2 Digital I/O Module NIB

Texas Instruments 505-4632

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UBR7200-NPE-G1 CISCO UBR NPEG1 ENGINE W/ 512MB D/64MB F 3 GE/FE/E

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Modicon DB-043505843

Schneider Modicon /Schneider Electric AS-M480-004/ASM480004

Schneider Modicon ASB233501 Input Module AS-B233-501

Schneider Modicon AS-BDEP-211 INPUT MODULE FACTORY SEALED

Schneider Modicon AS-BDAP-217 Output Relay ASBDAP217

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Schneider Modicon DEP 209 AS-DEP-209 /

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SIEMENS SAJO Sinumerik 8 MC 8MC HMC 600 800 G54 G55 G56 G57 G59

MITSUBISHI A1SJ71C24-R2 COMMUNICATIONS MODULE RS-232-C UNIT

SIEMENS Simodrive 6SN1123-1AA00-0AA0 _ 6SN11231AA000AA0

SIEMENS SINUMERIK 840DE NCU 561.2 6FC5356-0BB11-0AE0

SIEMENS /MOORE 39VIMCBN APACS VIM MODULE 16171-121/5

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Allen Bradley SLC 500 1746-OA8 1746OA8 Output Module Ser A NOB

ABB Robotics API Elmo PS 90/6-57-P-LSS-4404 AC Servo Motor 3 HAC 3403

A06B-0147-B075#7076 FANUC SERVO MOTORS REMANUFACTURED

0300P-4NAN-0001 REULAND AC SERVO SPINDLE

NACHI BUY-222 USPP BUY222

ALLEN BRADLEY 1756-L55M16 NSPP 1756L55M16

ALLEN BRADLEY 1336-BDB-SP30D USPP 1336BDBSP30D

GENERAL ELECTRIC 531X300CCHATM3 USPP 531X300CCHATM3

SST XL-S-2 USPP XLS2

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Siemens Inverter Module 6SE2100-1BB35

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TDK PD14A

SIEMENS INTERFACE MODULE 6ES5-318-8MA12

AVAILABLE SERIES A F/W REV A

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Schneider Modicon AS-BDAP-210 OUTPUT MODULE NNB

Schneider Modicon ASB872011 TESTED Analog Output Module AS-B872-011

Schneider Modicon AS-B862-001 USPP ASB862001

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SIEMENS 6ES5 464-8MC11 ANALOG INPUT MODULE 4POINT 10V

RME FireFace800 Fireface 800 PROAUDIOSTAR

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SIEMENS CONTROLLER CARD 6SN1122-0BA11-0AA1

SIEMENS SUN XS6-FC-LXXX-S8-CKZ SDLT600 FC Tray Kit SL8500

SIEMENS 6FC5012-0CA03-0AA0 6FC50120CA030AA0 version A

AllenBradley2711-K9C9PanelView900OperatorInterfaceSeriesCRev.A

Allen Bradley Versa View 1700P - 6181F-17TPXPH Series D

ABB INVERTER MODULE DRIVE ACS600 ACS 600 ACN634 ACN6340100600000300902

Advanced Energy PDX 2500 RF Generator, 4

(no lot#) Allen Bradley SMC Dialog Plus Drive 150-B180NBD 180A

MEASUREX 08622000 USPP 08622000

ALLEN BRADLEY 1336E-B050-AE-EN-HA2-L8E NSPP 1336EB050AEENHA2

GE FANUC IC752DPA262 USPP IC752DPA262

FANUC A16B-1210-0030/06F USPP A16B1210003006F

SIEMENS 6DD1-606-3AC0 USPP 6DD16063AC0

RELIANCE ELECTRIC 45C-200-A NSPP 45C200A

SIEMENS 6FX1-113-6AA00 USPP 6FX11136AA00

Siemens 6ES5 470-7LA11 6ES54707LA11

Siemens 6ES5 948-3UA13 948ucpu

SIEMENS 6ES5-441-4UA11 USPP 6ES54414UA11

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Siemens S5 6ES5420-4UA12 6ES54204UA12

Siemens C98043-A1261-L2-05

Siemens 6ES5 470-4UC12 6ES54704UC12

Square D 8030 CC-20

OMRON C500-II002 I/O Interface Unit PLC Module

WS-C2970G-24TS-E CISCO Switch w/1year -WSC2970G24TSE 2970G24TSE

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Siemens Simovert Pulse Converter 6SE60 20-1BF00 6SE6020-1BF00 G32970-A0035-A204

Rice Lake Weighing Systems IO-810-3A

Schneider Modicon AS-P120-000 SEALED IN BAG ASP120000

Schneider Modicon AS-B551-001 NSFP ASB551001

Schneider Modicon AS-W600-009 USPP ASW600009

Schneider Modicon AS-BDEP-217 ASBDEP217 24VDC Input LNC

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MODICON ANALOG OUTPUT MODULE AS-B872-011

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SIEMENS SINUMERIK 6FC3538-3EF 6FC35383EF

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