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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。
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