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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。

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

Siemens 6ES7321-1BL00-0AA0 6ES7 321-1BL00-0AA0 NIB

Modicon AS-P180-011

Omron C500-ID218

Schneider Modicon DAP-220/AS-BDAP-220 Discrete Combination ASBDAP220 NIB

Schneider Modicon AEG/GOULD// AS-B573-010 OUTPUT MODULE XLNT

Schneider Modicon AS-884A-200 USPP AS884A200

Schneider Modicon AS-P120-000 USPP ASP120000

Schneider Modicon AS-B239

Schneider Modicon AS-516P-008 CNC Memory Board AIPR/UVG

Modicon XBT FC044610 Telemecanique Magelis 24VDC 35W

Siemens Simatic S7-200 PLC 6ES7 221-1BF22-0XA0 DC Input Module

TELEMECANIQUE TSX-ASZ-200 TSXASZ200

Siemens Simatic Relay Output Module U-05T

Siemens 9610 9610DC-1155-GZZA Power Meter Display ION Ethernet Access NNB

SIEMENS Sinumerik FPCI/ISA 6FC5247-0AA02-1AA0 6FC5 247

SIEMENS 6SN1118-1NH00-0AA2 6SN11181NH000AA2

SIEMENS SIMODRIVE 6SN1123-1AA02-0FA0

SIEMENS I/O MODULE 6FC3984-3RA 6FC39843RA 64E/32AUSGAEN

Advantech PCM-3810 A2 PC/104

Allen-Bradley 2711-K5A8 PanelView 550 Operator Interface Panel

ABB 5SDD0760D0001 3BHL001862P0001 Thyristor for ACS1000 AC Drive

Acrison 305-0096 Gearbox BDF1.5 OUT THD

AAT-SOT23-5-AAT1106 2-CHANNEL STEP-UP PWM IC Controller

85179 , Dayton 1LNF4 AC Adj Frequency Drive, 20 HP, 3 PH, 460V

SIEMENS 6SE3-121-7DG40 NSFP 6SE31217DG40

ATLAS COPCO PF2102-S7-115R USPP PF2102S7115R

ASEA BROWN BOVERI DSQC 314B USPP DSQC314B

MITSUBISHI Q173-CPU-N USPP Q173CPUN

INDRAMAT MAC-132A-1-JD-4-C/230-R-0/DIS20LX/S001 USPP MAC132A1JD4C230R

ASEA BROWN BOVERI 3HAB2220-1 USPP 3HAB22201

TEXAS INSTRUMENTS PLC 500-2102 NSPP 5002102

Siemens 6ES5-441-4UA14 USPP 6ES54414UA14

SIEMENS 6ES5 482-8MA13 DIGITAL I/O MODULE

SIEMENS S5 6ES5 308-3UA12 Serial Interface 6ES53UA12

Siemens S5 6ES5 470-7LB12 Analog Output 6ES5470-7LB12

SIEMENS 6ES7 621-6BD01-0AE3 SIMATIC S7 C7-621 ASI Worldwide

Siemens S5 6ES5 928-3UB21 S5 6ES5928-3UB21 CPU CPU928B

PPT Machine Vision Impact C40 Processor Cables I/O Bd

Honeywell Ademco 4100SM Serial Interface Module

VW Volkswagen Jetta Golf GTI Bluetooth Interface Communication Module 1K8035730D

SIEMENS 6DS1212-8AB

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

Omron 3G2A5-OC224

Schneider Modicon AS-P120-000 PLC

Schneider Modicon LEVEL-3 16K 3CARD CHASSIS 584 AS-584A-320

Schneider Modicon AS-H819-100 USPP ASH819100

Schneider Modicon Gould/ AS-984A-008

Schneider Modicon AS-BDAP-218

Schneider Modicon REED RELAY OUTPUT MODULE AS-B840-108 REPAIRED

Telemecanique HMI to Allen Bradley Logix1000 Cable

Schneider TELEMECANIQUE Modicon TWDNCO1M

Siemens6AV6641-0AA11-0AX06AV66410AA110AX0Panel

Siemens 6AV6 545-0BA15-2AX0 6AV65450BA152AX0 Panel

SIEMENS Sinumerik 6FC5111-0CA02-0AA2 DMP KOMPAKT 16A 24V/0.5 E-Stand A

GE FANUC COMMUNICATIONS CONTROL MODULE IC693CMM311R

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

SIEMENS SINUMERIK 12.1" TFT OPERATOR INTERFACE PANEL 6FC5203-0AF02-0AA1

SIEMENS IBM 6400 Model 010 Printer Ribbons - IBM 6400 Model 10

ALLEN-BRADLEY DATALINER OPERATOR INTERFACE CAT2706-D21J8

A-B NIPPONDENSO 8500-B1C-L1B Motors-AC Servo [PZ4]

AC Motor Invertor - 30 HP - 600 Volt - Three Phase Input

A06B-0602-B027 GETTY'S DC SERVOMOTOR MODEL 20

750' Rider 500-500-350 USE Wire Direct Burial Aluminum Triplex

RELIANCE ELECTRIC S6R-9006 NSFP S6R9006

ALLEN BRADLEY 5250-LP3 NSFP 5250LP3

ALLEN BRADLEY 20AB070A0AYNANC0 NSFP 20AB070A0AYNANC0

INDRAMAT KDV1.3-100-115 USPP KDV13100115

YASKAWA ELECTRIC CACR-W57-FJ4ER USPP CACRW57FJ4ER

WESTINGHOUSE 292B315A19 USPP 292B315A19

IAI RCS-SSI-60-H-400-S-B USPP RCSSSI60H400SB

Siemens 6ES5-244-3AB31 USPP 6ES52443AB31

SIEMENS 6ES5 376-1AA31 6ES53761AA31

SIEMENS Interface Module 6ES5-312-5CA11

Siemens Analog Input Module 6ES5-460-7LA11

Siemens 6ES7 131-1BL01-0XB0 6ES7131-1BL01-0XB0 FreeShip

Siemens MP370 6AV6 545-0DA10-0AX0 Touchscreen Glass 12"

RELIANCE 57C416/0-57416 REMOTE I/O COMM MODULE NIB

Texas Instruments 505-4516

Stock Quantity Worldwide Shipipng BRAND RETAIL

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

Siemens Controller ACX32.000/ALG

Modicon CM 1000

Schneider Modicon NIB AS-HBOX-201 3 1/2 DISKETTE STORAGE BOX

Schneider Modicon AEG/GOULD/MODICON/ AS-S480-207 MEMORY CPU BOARD XLNT

Schneider Modicon AS-BDEP-209 NSFP ASBDEP209

Schneider Modicon AS-BDAP-216N

Schneider Modicon -AS-506P-004

Schneider Modicon DAP 218/AS-BDAP-218 TSX Compact Output Module H13 817

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 DMP 16-E MODULE 6FC5111-0CA01-0AA0

RELIANCE ELECTRIC 57C404B COMMUNICATION MODULE NETWORK

SIEMENS CONTROLLER CARD 6SN1118-0NH11-0AA0

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

AllenBradley2711-K9C9PanelView900SeriesARev.A

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

ABB IMMOTION YGBF-20 FIELD CONVERTER EXCITER CONTROL MODULE 64G069D- 60835

Advanced Energy MDX Pinnacle DC Magnetron Power Supply AE 3152363-004A ~208

(N3-3) 1 FISHER ROSEMOUNT 41B5215X13R DISCRETE I/O CARD N3-3

MEASUREX 08495006 USPP 08495006

ALLEN BRADLEY 1336-B050-ECG-L3 USPP 1336B050ECGL3

GE FANUC IC697CGR935 USPP IC697CGR935

FANUC A16B-1010-0050 USPP A16B10100050

SIEMENS 6AV7-800-0BA00-1AC0 NSFP 6AV78000BA001AC0

RELIANCE ELECTRIC 30FR7731 USPP 30FR7731

SIEMENS 6EV3053-0CC USPP 6EV30530CC

Siemens 6ES5 470-4UC12 6ES54704UC12

Siemens 6ES5-947-3UA21 USPP 6ES59473UA21

SIEMENS 6ES5-440-8MA21 NSPP 6ES54408MA21

Siemens 6ES5 900 0AA11 6ES5-900-0AA11 807 1024 001 807-1024-001 BL2A SPCB460

Siemens S5 6ES5 951-7LB14 6ES59517LB14

SIEMENS C98043-A1200-P4

SIEMENS 6ES5 482-4UA11 DIGITAL I/O MODULE

Square D 8030 CBP-107

OMRON C200H-IP006 PERIPHERAL INTERFACE MODULE

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

Siemens 6ES7315-1AF01-0AB0 CPU315 6ES73151AF010AB0

Siemens Simodrive C98043-A1204-L Control Board

Reliance WU4001179

Schneider Modicon AS-P120-250AC Pwr Sply Ext Temp ASP120250

Schneider Modicon AS-B547-000 USPP ASB547000

Schneider Modicon AS-W600-003 USPP ASW600003

Schneider Modicon ASBDEP210 REMAN AS-BDEP-210

Schneider Modicon AS-B825-016/ASB825016 Input Module

Modicon Analog Output Module AS-B872-200 ASB872200

SIEMENS EM221 INPUT MODULE 6ES7 221-1EF22-0XA0 6ES7221

Sharp JW-34NC I/O Module

Siemens Operator Interface 6SE32900XX878BF0 23884

SIEMENS SINUMERIK 6FC 3741-0FB-Z CONTROL RACK XLNT

Synchronous Communications Inc Agile Modulator FAOC-60

SIEMENS 6SN1118-1NH00-0AA1/6SN11181NH000AA1 BOARD RFB

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 JDSU ANT-20 SE Advanced Network Tester ANT-20

6ES5252-3AA13

8520-VOP ALLEN BRADLEY MONITORS CRT REMANUFACTURED

SIEMENS 6SE7-018-0TA20 USPP 6SE70180TA20

BAILEY CONTROLS IMMFP-02 NSPP IMMFP02

ASEA BROWN BOVERI YT204001-AA USPP YT204001AA