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國(guó)內(nèi)的包裝生產(chǎn)線在發(fā)展初期一般只能完成物料包裝，后續(xù)的搬運(yùn)工作則由搬運(yùn)工人來(lái)完成。隨著產(chǎn)量的日益擴(kuò)大，傳統(tǒng)的人工搬運(yùn)方式顯然無(wú)法滿足需求，碼垛機(jī)械的出現(xiàn)為這一問題提供了有效的解決方案。
　　碼垛機(jī)可以集成在生產(chǎn)線中，使生產(chǎn)現(xiàn)場(chǎng)變得智能化，可以實(shí)現(xiàn)飲料、食品、日化等行業(yè)各種作業(yè)的碼垛物流，為企業(yè)改善工作條件，減輕個(gè)人體力勞動(dòng)，減員增效起到了關(guān)鍵作用。目前主流的控制系統(tǒng)采用 PLC+ 機(jī)械手的方式，對(duì)整條生產(chǎn)線的末端產(chǎn)品進(jìn)行整理、堆疊、整垛輸出等。
　　目前市場(chǎng)上主流的碼垛線為單線輸送系統(tǒng)，碼垛能力在 30~40 箱 / 分，具體的碼垛能力視貨物而異。本項(xiàng)目中設(shè)計(jì)的碼垛線為雙線輸送，碼垛能力能達(dá)到 60 箱 / 分，主要應(yīng)用在食品行業(yè)。該碼垛線通過(guò) PLC 控制將兩條生產(chǎn)線上輸送過(guò)的產(chǎn)品分別輸送到對(duì)應(yīng)的堆疊區(qū)，且通過(guò)觸摸屏可設(shè)定不同的層數(shù)采用不同的堆疊方式，如第 1 層按方式 1 堆疊，第 2 層按方式 2 堆疊，碼垛方式靈活。
　　2 工藝要求
　　碼垛線分為 A、B 兩線，每條線均由以下部分組成：入口輸送帶 1、入口輸送帶 2、入口輸送帶 3、分離電機(jī)、轉(zhuǎn)向電磁閥、轉(zhuǎn)向滾筒、堆疊輸送帶，出口輸送帶等;A、 B 兩線共用棧板供應(yīng)系統(tǒng)和左右棧板輸送帶等設(shè)備。碼垛線裝備實(shí)物圖片如圖 1 所示。
貨物由入口輸送帶1進(jìn)入，經(jīng)過(guò)三個(gè)入口緩存輸送帶，輸送到分離電機(jī)處;分離電機(jī)分離后根據(jù)需要確認(rèn)是否轉(zhuǎn)向 ( 如需轉(zhuǎn)向則轉(zhuǎn)向氣缸動(dòng)作 ) 并計(jì)數(shù)，PLC 進(jìn)行判斷產(chǎn)品是否已完成一列。達(dá)到一列后控制推桿動(dòng)作，將貨物整平。此時(shí)，PLC 發(fā)出 DO 信號(hào)給 ABB 機(jī)械手 (ABB 機(jī)械手與 PLC 通過(guò)硬接線連接 )，機(jī)械手動(dòng)作抓取已完成碼垛的一列產(chǎn)品;當(dāng)完成一垛后，堆疊電機(jī)動(dòng)作，將已完成堆垛的貨物整垛輸出;然后棧板供應(yīng)啟動(dòng)，為缺少棧板的堆疊區(qū)提供棧板，依次循環(huán)實(shí)現(xiàn)持續(xù)碼垛。其工藝流程如圖 2 所示。
　3 自動(dòng)化平臺(tái)選型
　　鑒于該碼垛機(jī) I/O 點(diǎn)數(shù)較多 (DI 為 75，DO 為 40)，以及電控柜空間限制的需求，在系統(tǒng)選型時(shí)采用西門子 S7-200 SMART PLC 作為主控制器，因?yàn)?S7-200 SMART 具備 60I/O 的大點(diǎn)數(shù) CPU 以及高密度擴(kuò)展模塊，并且模塊體積緊湊，能夠有效滿足以上需求。碼垛線上的轉(zhuǎn)向氣缸、滾筒等動(dòng)作頻繁，高達(dá) 20~30 次 / 分，故采用晶體管輸出類型，外接中間繼電器驅(qū)動(dòng)大負(fù)載。在HMI選型上，單線系統(tǒng)選用7寸屏即能滿足要求，但對(duì)于雙線控制系統(tǒng)，需要顯示的信息更多，最終選用 10 寸屏。同時(shí)，屏上集成的以太網(wǎng)接口與 S7-200 SMART 無(wú)縫連接，編程調(diào)試、設(shè)備通訊都很方便。電控系統(tǒng)配置如附表所示。
4.1 結(jié)構(gòu)化模塊設(shè)計(jì)
　　由于碼垛線控制點(diǎn)數(shù)較多，程序較大，而且各部分功能較為分明，所以在軟件設(shè)計(jì)時(shí)，采用結(jié)構(gòu)化編程的理念可使程序結(jié)構(gòu)更加分明。程序設(shè)計(jì)分為主程序和子程序兩部分，主程序中 AB 兩線運(yùn)行各自調(diào)用相應(yīng)子程序。子程序主要有：開機(jī)初始化程序、各設(shè)備手動(dòng)控制程序、入口計(jì)數(shù)子程序、整列推桿初始化子程序、自動(dòng)運(yùn)行子程序、堆疊方式處理子程序、故障報(bào)警子程序、系統(tǒng)復(fù)位及數(shù)量清零等子程序組成，如圖 3 所示。

COGNEX 800-5838-4 NSPP 80058384

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FANUC A02B-0094-C041 USPP A02B0094C041

ROBERTSHAW DMS-3501 USPP DMS3501

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Siemens S7-200 EM231 6ES7 231-0HC20-0XA0 EM 231

Reliance 45C340

Schneider Modicon GOULD REMOTE I/O RECEIVER MODEL AS-J821-001

Schneider Modicon AS-B350-001 OUTPUT MODULE B350 115 VOLT AC

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Schneider Modicon AS-B805-016 B805 115 VAC INPUT

Modicon Controller Part AS-P464

SIEMENS S5 6ES5 421-8MA11 Digital Input Module8DI 24V

Siemens 6ES5 464-8MC11 -FS- 6ES54648MC11

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SIEMENS 6SN1118-0AD11-0AA0 6SN11180AD110AA0

SIEMENS SIMODRIVE 611 6SN1123-1AA00-0CA2 POWER MODULE 6SN11231AA000CA2 (NIB)

SIEMENS 6FC5510-0BA00-0AA0 USPP 6FC55100BA000AA0

Advantech PCA-6186VE PCA-6186 Rev.A1 NIB

Allen-Bradley 1771-OA AC OUTPUT MODULE

ABB ASEA BROWN BOVERI POWER ITE AIR CIRCUIT BREAKER 800A 800 AMP KDON K-DON 800S

ADEPT 90400-60131 AMPLIFIER MODULE MEGATORQUE 300 WATT CONTROLLER

6SE7026-0TP50 SIEMENS COMPACT + MASTERDRIVE 59AMP 30kW 510-620VDC MOTION CNTRL

SYMAX 8020-SCP-424 NSPP 8020SCP424

CUTLER HAMMER IDT0286 NSFP IDT0286

CLEVELAND MOTION CONTROL BNR5110GPA00CS0002 NSPP BNR5110GPAOOCS00

NEMATRON CORP IWS-4824 USPP IWS4824

MITSUBISHI FR-A520-2.2K-NA USPP FRA52022KNA

GE FANUC 44A719348-102 USPP 44A719348102

Siemens 6ES5 246-4UA11 6ES52464UA11

Siemens 6ES5-470-8MB11 NSFP 6ES54708MB11

SIEMENS 6ES5-306-7LA11 NSPP 6ES53067LA11

SIEMENS S5 SERIAL INTERFACE 6ES5 521-8MA21

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SIEMENS 6FC5203-0AF50-3AA1 6FC5 203-0AF50-3AA1 MCP416C

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Jova Solutions TIMS-0102 USB 12C/SPI Interface Module

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Siemens OP17 6AV3617-1JC20-0AX1 Membrane Keypad , ping worldwide

Patriot WA0750

Schneider Modicon AS-B872-002/ASB872002 Output Module OFFERS ACCEPTED

Schneider Modicon AS-5540-006 NSFP AS5540006

Schneider Modicon AS-M680-108 Memory Module

Schneider Modicon AS-9490-004 USPP AS9490004

Schneider Modicon 800 SERIES 11 SLOT RACK AS-H827-103

Schneider Modicon TSX COMPACT DISCRETE INPUT DEP 216 AS-BDEP-216 LOT OF 5

Siemens TI 505-4108 Low VDC Input Module

Telemecanique ATV11HU09M3A 0.37kW Inverter in Box

SIEMENS SIMATIC SM422 DIGITAL OUTPUT MODULE S7-400 ++

SIEMENS 4700 POWER FUNCTIONS METER OPERATOR INTERFACE PANEL 4700-BDRMC3-11HN

SIEMENS Sinumerik 840C/840CE P/Supp 6FC5114-0AA01-1AA0

CC LINK COMMUNICATIONS MODULE MITSUBISHI FR-E5NC

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SIEMENS Servo Drive 6FC5247-0AA00-0AA3 6FC52470AA000AA3

Advantech PCA-6184V, no ethernet port,

Allen-Bradley 2711-T6C15L1 Panelview 600

ABB 3HNE00313-1

ACCURAY AIC8 086155-001 SCANNER MODULE CARD CONTROLLER B211850

A2LA 17025 Accredited Calibration with full Data Report

82-1/2" OVER ALL LENGTH 2-1/4" DIAMETER BALLSCREW 55" TRAVEL 5-1/2" FLANGE

SIEMENS 6ES7-623-1DE01-0AE3 USPP 6ES76231DE010AE3

ASEA BROWN BOVERI 750191-001B NSFP 750191001B

ALSTOM ALSPA-MV-1013 USPP ALSPAMV1013

MICRO MOTION DL065-S242SU NSPP DL065S242SU

HUB CITY 88 NSFP 88

ALLEN BRADLEY 1774-KA USPP 1774KA

SIEMENS 6ES5-925-3SA11 USPP 6ES59253SA11

Siemens 6ES5-391-5AA13 USPP 6ES53915AA13

SIEMENS 6ES5 454-7LA11 6ES54547LA11

SIEMENS 6ES5 465-7LA13 Module

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Siemens 6ES7 323-1BH01-0AA0 6ES7323-1BH01-0AA0 FreeShip

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PVDM3-32 CISCO 32-CHANNEL HIGH-DENSITY VOICE AND VIDEO DSP MODULE

GSM/GPRS Modem Pool 8 Ports USB interface Wavecom Module AT Commands Q2406

Unico 314-739 314739 Interface Module No Box

Siemens 6AV6 640-0DA11-0AX0 Touch Panel NIB

Siemens Logo 230RC 6ED1 052-1FB00-0BA3

MTT ms2304

Schneider Modicon Connector/Cable AS-W801-002/ASW801002

Schneider Modicon 800 SERIES AS-H827-103 11 PORT RACK ASH827103

Schneider Modicon AS-E685-904 NSFP ASE685904

Schneider Modicon Gould AS-B804-016 OUTPUT MODULE 16POINT 115VAC ANALOG

Schneider Modicon AS-B804-016

Schneider Modicon Output Module True High AS-B820-008

Schneider TWIDO TWDNOZ485T Expansion, Comm, RS485 Tbk

Schneider Modicon TSXPCX1031-C TSXPCX1031C PLC Cable

SiemensSimatic6AV6641-0CA01-0AX16AV66410CA01

Siemens 6AV6642-0BC01-1AX0 6AV6 642-0BC01-1AX0 SIMATIC TP177B 6" Touch Panel

SIEMENS S5 6DD2920-0AS0 INTERFACE MODULE PULSE CIRCUIT

GE Fanuc IC697RCM711C Redundancy Communications Module

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SIEMENS MOORE 750E111GNNNF ELECTRONIC PNEUMATIC VALVE POSITIONER AIR 750E 20113

Allen-Bradley Panel View 600 Plus

AB 1336E-B015-AA-EN 460V 15HP IMPACT DRIVE QUANTITY TESTED

ABB/ACS 500 150 HP Drive 440-500 VAC Cat# H502125400P2BBB200 3000

A06B-0332-B069#7000 FANUC SERVO MOTORS REMANUFACTURED

75 HP ELECTRIC MOTOR 1200 RPM 405T FRAME NEMA PREMIUM EFFICIENT SEVERE DUTY

RELIANCE ELECTRIC 6V41-096TA NSPP 6V41096TA

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ALLEN BRADLEY 1771-IF05 USPP 1771IF05

HONEYWELL 30731737-006 NSFP 30731737006

WESTINGHOUSE DBL-25-1200 USPP DBL251200

TEXAS INSTRUMENTS PLC VPU500-3104 USPP VPU5003104

GENERAL ELECTRIC DS3800DMEC1D1D USPP DS3800DMEC1D1D

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Texas Instruments 500-2151

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VIA Artigo A2000 Barebones Storage Server 1.5 GHz VIA C7-D Brand

Siemens C98043-A1604-L3-03 no packaging

Modicon AS-W510-002

Schneider Modicon Automation AS-BDEP-216 Discrete Input -

Schneider Modicon AS-H819-209 CHASSIES ASH819209

Schneider Modicon AS-BDAP-112 USPP ASBDAP112

Schneider Modicon ASB872002 Excellent Analog OUT Module AS-B872-002

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

Schneider Modicon AS-W801-006 ASW801006 Extender Cable NIB

Schneider Modicon 140CRA93100 / 140CRA 931 00

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MODULE COMMUNICATION ALLEN BRADLEY 1203-GD1

SIEMENS SIMODRIVE 611 BOARD 6SN1118-0DJ21-0AA1NIB

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ALLEN-BRADLEY1756-OFCI/AOUTPUTMODULE1756-0FCI

Allen Bradley SLC 500 Output Module 1746-OX8 Ser. A

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0.1-1250 μm LPA-9Z Desktop Intelligent Laser Particle Size Analyzer Sizer

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ADEPT TECH 10332-00500 USPP 1033200500

GE FANUC IC640WMI910 NSFP IC640WMI910

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Schneider Digital Input Block Fuse 140CFB03200 3436

Square D 9006-PBF121

Siemens 6ES7460-0AA01-0AB0 SIMATIC S7-400 IM460-0 Transmitter Interface Module

WE SHIP SAME CISCO SLM2024T SG200-26 SLM2024T-NA 26PORT GIGABIT SMART

Siemens 6RA7018-6DV62-0-Z 6RA7018-6DV62-0 DC DRIVE

Siemens TP27-10 6AV3 627-1QL00-0AX0 Touch Glass, Bergquist Touch Products

Schneider Modicon TSX COMPACT DISCRETE OUTPUT AS-BDAP-210 4

Schneider Modicon ASBDAP210 AS-BDAP-210Compact output

Schneider Modicon AS-B825-016 NSFP ASB825016

Schneider Modicon MODULE AS-E908-131 S35D

Schneider Modicon AS-W192-015

Schneider Modicon AS-BZAE-204 HIGH SPEED COUNTER IN BOX FACTORY SEALED

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AllenBradley6182H-10TLH4DVersaViewCE1000HWorkstationPanel

Allen Bradley VersaView Display 17" to 19" Repair Service $169.99

ABB E2N-A16 600V 2000A PR121/P L/S/I INSULATED CASE CIRCUIT BREAKER

Adtech AX4000 LOADED WITH CARDS

(H13) 1 CUTLER-HAMMER LDB2600W SEALED BREAKER H13

KELLER TECHNOLOGY CORP 14449-5011 NSPP 144495011

ACUITY IMAGING 002-PV9040 USPP 002PV9040

FLUID POWER DIVISION PMC-20E USPP PMC20E

FANUC A06B-0143-B175 USPP A06B0143B175

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RAPID POWER TECH SPSAA100012 USPP SPSAA100012

RELIANCE ELECTRIC 86466-47T NSFP 8646647T

Siemens 6ES5 460-4UA13 -FS- 6ES54604UA13

Siemens 6ES5-928-3UA11 USPP 6ES59283UA11

SIEMENS 6ES5-430-7LA11 USPP 6ES54307LA11

Siemens 6ES5 490-7LB21 CONNECTOR IN BOX

Siemens S5 6ES5 464-8MC11

SIEMENS 802Dsl Membrane Keypad

SIEMENS 6ES7 223-1BL22-0XA8 EM 223 CN I/O MODULE

Square D 8005 MP-1

Nokia NIF4303FRU 2-Port X.21 PMC Interface Card Module

WS-F6K-DFC3A DIST FWD CARD-3A FOR 65XX 6816 MODULES WITH SUP720

SIEMENS 6ES7-151-1AA03-0AB0

Siemens SCD 1597-ET 6AV8100-1BB00-0AA0

Reliance 45C940

Schneider Modicon GOULD B805 AS-B805-016 INPUT MODULE 115 V AC

Schneider Modicon AS-B352-001 USPP ASB352001

Schneider Modicon AS-S908-021 USPP ASS908021

Schneider Modicon AS-B883-101

Schneider Modicon AS-B807-032 120VAC INPUT

MODICON AS-BDAP-210 DISCRETE OUTPUT MODULE

SIEMENS MODULE DIGITAL INPUT 505-4316A 5054316A

Siemens 6ES5 451-4UA13 -FS- 6ES54514UA13

Siemens PLC Output Module 6ES7 135-4FB01-0AB0 6ES71354FB010AB0 NIB