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UNYCSPSPUXZBU,

UNYCSPSPUXZBU

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。

上亿库存，国内外近千个仓库，公司部分产品型号如下，欢迎联系哦~！

Motion Control MPL-B4530K-MK22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,460V

Motion Control 2090-S-BLHD SERCOS FIBER CABLE BULKHEAD ADAPTOR 2 PER

CBL-RKLK-10 Rack Linker Cable, Target ARS Series Controller

IC300RCS077 14 AC Inputs (120vac), 10 Relay Outputs (2.5A per point). Built-in network interface for CsCAN or DeviceNet slave.

IC693CPU360LT CPU 360 Module (240K Bytes configurable user memory, 4K I/O, 8 Racks), no built-in Serial Ports .22msec/K (LT)

MTR-1350-N-A-E-S MTR series NEMA 34 splashproof stepping motor with parallel winding connection

20AD8P0A0NYNANC0 PowerFlex 70 AC Drive 8 A at 5 Hp 20A

20C-CPBS00000000D5 PowerFlex 700 H Control Assembly

20F11RC8P7JA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A2P3N104 PowerFlex 4- 0.4 kW (0.5 HP) AC Drive

140CHS32000 Quantum QUANTUM 热备远程I/O同轴电缆终结套件

28319-801-01 Limit Switch O-Ring

C200H-NC112 位控单元,伺服驱动 范围1-250000PPS 1轴

1492-RCDA4B25 Residual Current Device 25 A

同步模块 6ES7960-1AA04-0XA0 同步模块

变送器 3RS10 41-2GW50

1497-G-M4-3-N Control Circuit Transformer

1606-XLE120E-2 480VAC Input 24VDC Out 5A Power Supply

1762-OX6I MicroLogix 6 Point Relay Output Module

188-K3D100 Miniature Circuit Breaker 10 A

194L-HCDH-001 IEC Control And Load Sw Actuator

2090-CPBM7DF-08AA04 MP-Series 4m Power and Brake Cable

2090-XXNPMF-14S05 Kinetix Drives 5m Standard Cable

BC647TPR300 CIMPLICITY HMI ProServer 300 I/O Runtime System with Proficy GlobalCare

GC647PRTRO GlobalCare Complete - Proficy Portal Read Only Option Ver 3.0

IC200MDL744LT OUTPUT 5/12/24VDC NEG LOGIC 0.5A PER PT (2 GROUPS OF 16) 32PT (LT)

IC646PHD935 PH-70H with 935 CPU - DC

IC647MT1C MT1:Met One

IC684TROLI601 CIMPLICITY HMI Plant Edition Online Course -Module 1

IC697VAL264 Relplacement is Embedded VME-3122A-400000. Contact GE IP Embedded for details.

IC800SSI228RD2RR 28A, 230V, DeviceNet S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L551 SLC 5/05 CONTROLLER

Industrial Computers 6181P-12NSXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 12-INCH TFT

Application-specific products 9358-PBANT60ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 60 UNITS

Operator Interface 2711-K5A10L1 PV550 MONOCHROME KEY, DNET & RS232 PRINT

Support 9306-4EXP01ENS SUPT RENEWAL CONTRACT FOR 93064EXP01ENE

Support 9393-RSTACDS SUPT RENEWAL CONTRACT FOR 9393RSTACD, 9393RSTACD

ControlNet Products 2711-K10C15L1 PV1000 COLOR KEY, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500PTU3 RSVIEW32 WORKS 300-100K UPGRADE IN-SUPT (PT)

RSI Software Products 9358-BEPB30ENE RSBIZWARE BATCH AND EPROCEDURE BUNDLE 30 UNITS

Motion Control MPL-A4540C-SJ22AA MOTOR,SERVO,10.2 NM,1500RPM,SINGL,230V,9.5KG

Motion Control 2090-XXNFY-S01 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,1M

CBL-T7-MP-20 Power Cable, MTR-3T1x & MTR-3T2x Series Servo Motors, 20 Ft.

IC641PCC122 Logic Engine (runtime) w/o GUI - 128 Points

IC800SSD216S1 16 Amp S2K Series Servo Amplifier, 230 VAC

PR-PAT-DX-1.2 Proficy DX, PAT Software, Non Pharm

20BB-DB1-1 PowerFlex 700 Resistor Kit

20DD730A0ENNBNANE PowerFlex 700S AC Drive 730 A 600 Hp 20D

20YD460W0ANNANA0 PowerFlex 700AFE 460A Active Front End

2711P-B7C4D9 PanelView Plus Terminal

280-PWRM35C-M3 ArmorStart Three-Phase Power Media

CQM1-PR001-E 编程器 带电缆1.5米

1492-MS5X12V1-10 Connection Products

1495-N61 Protective Fuse Cover

行程开关 3SE53120SE11

运行版软件 6AV2105-0TA04-0AA0 SIMATIC WinCC Runtime 专业版 262144 PowerTags V14

1585J-M4TBJM-6 RJ45 Ethernet Media

1756-OF8IH ControlLogix 8 Pt A/O HART Isolated

188-K1C060-N 6 A Miniature Circuit Breaker

194E-HE4G-175 194E Load Switch Actuator

2090-CFBM7DF-CEAA09 MP-Series 9m Servo Feedback Cable

2090-UXLF-123 Ultra Series 23A AC Line Filter

BC646PEW100 OP EWS Development Software Unltd I/O w/GC

GC647IFCLNTCRN GCC iFIX iClient Run

IC200ALG266 Analog input 15 bit, 4-20mA, current, 15 channel. TUV approved.

IC646IFCLNTCRO050K iFIX iClient Read Only 50 PK Keyless (M1 Kit Part)

IC647IFPRDV00150K iFIX Profsnl SCADA 150 I/O Development (M1 Kit Part)

IC660SLA021 Red Safety Label Kit for IC660BBA021Genius Blocks

IC697BEM763RR DLan Interface

IC800BIK040 BSVM1-40i Beta i 40 amp amplifier kit

ControlLogix/1756 System 1756-L61 LOGIX5561 PROCESSOR WITH 2MBYTE MEMORY

Industrial Computers 6182H-7BRH4D VVCE 700, KEY/TOUCH, STD MEM, ENET, DC

Process Control 9358-PB10ENE RSBIZWARE BATCH FOR PROCESSLOGIX 10 UNITS

Operator Interface 2711P-K15C4B1 PV PLUS 1500, KEYPAD, ENET, AC PS, STD MEM

Support 9352-WAB300S SUPT RENEWAL CONTRACT FOR 9352WAB300

Support 9308-RSFBENU1 UPGRADE RSFIELDBUS CONFIG SW 64 TO 256 FB

Support F5250-LP2 FIRMWARE UPGRADE FOR 5250-LP2 PLC5250 PROCESSOR MO

RSI Software Products 9301-2SE2353DEE RSVIEW32 WORKS 5K WITH RSLINX (GERMAN)

RSI Software Products 9351-SLRSRT INTERCHANGE FOR SOLARIS RUNTIME

RSI Software Products 9399-WINIGFR INSTAL'ION GUIDE FOR WINDOWS-BASED PROD.(FRENCH)

Motion Control 8720MC-RPS065BS-HV1 SLAVE RPS WITH VARISTOR AND HARMONIC FILTER

BC646MRE700 Logic PC & View Runtime (HRT) 700 I/O

IC300THM200 18-bit, 8 channel Thermocouple Inputs (J, K, T, E, +/-25mV, +/-50mV, +/-100mV), 0.05 degree Centigrade resolution

IC754VSB06MTD 6" Monochrome Quickpanel View Basic, Touch, 24VDC

MTR-3T66-H-R-0-M-0 MTR series metric servo motor with resolver

20AD011A0NYNACG0 PowerFlex 70 AC Drive 11 A at 7.5 Hp 20A

20DC037A3EYNAEASE PowerFlex 700S AC Drive 20D

20G1ANC302AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-A2P5N104 PowerFlex 527 0.4kW (0.5Hp) AC Drive

280-M35F-M3 ArmorConnect M35 Female Receptacle

FR-F740-37K 53.3KVA 70A 37KW 3相AC380V/50Hz/60Hz

1492-LG6T IEC Term Blck 8.1x90x38mm Spr Clp

1494G-BF3N-421 NEMA 1494G Enclosed Disconnect

软启动器 3RW44366BC45

ET 200SP 6ES7132-6BD20-0CA0 DO 4x24VDC/2A 高性能型，基座单元类型 A0

1585D-E4UBDE-4 Ethernet Media M12 Patchcord

1753-PCS-USBM GuardPLC RSLogix Guard PLUS USB MED S/W

1794-IE8XT Flex XT 8 Point Analog Input Module

194E-AA63E-PE-P11 194E Load switch

2080-LC30-48QVB Micro830 48 I/O Controller

2090-CSWM1DF-18AA09 Kinetix Cable Single DSL 2090-Series

20AC3P5A3AYYANC1 PowerFlex 70 AC Drive 20A

GC646MQPS99 Proficy GlobalCare Complete for View for QuickPanel - Unlimited Site License

HE693RTM705 Discontinued Part. Check with GE IP on migration path.

IC610MDL107RR 24Vdc Sink In, w/Removable Term. Block, w/LEDs (16 points)

IC647HSTSS100KM Historian Standard Server 100000 Points (M4 Key)

IC660BBD023RR 24Vdc Sink I/O Block, 16 Circuit, Ph B

IC694TBB032 Box Style High Density Terminal Block - 36 Connections

IC756WDN009K-20 DV Dev Sys(Ent) VB, C++, C, Kor v2.0

CompactLogix System 1769-L32E COMPACTLOGIX ETHERNET PROCESSOR, 750 KBYTE MEMORY

PLC-5/1771 System 1771-P7 POWER SUPPLY, 16A, 120/220V AC

Distributed I/O 1798-APB PROFIBUS DP ADAPTER

Operator Interface 2711P-K6C1D PV PLUS 600 COLOR, KEYPAD, SRIO, DC PS

Support 9323-PI300R SUPT REINSTATEMENT CONTRACT FOR 9323PI300

Support 9358-PBA03S SUPT RENEWAL CONTRACT FOR 9358PBA03ENE

Support F1775-GA FIRMWARE UPGRADE FOR 1775-GA PLC3 PROCESSOR MODULE

RSI Software Products 9324-RLD700NXESE RSLOGIX 5000 PRO EDITION, SPANISH

RSI Software Products 9305-RSVADFVCPTE RSVIEW32 ACTIVE DISPL FLOAT.VIEW CLNT (PORTUGUESE)

RSI Software Products 9308-RSFB1024ENE RSFIELDBUS 1024 FB BASE CONFIG SW

Motion Control 2094-PR2 POWER RAIL, 230V OR 460V, 2 AXIS

A06B-6073-K214 Connector, Beta Encoder (JF1), I/O Link Ext. Pulse Int. (JA34)

IC200UEX011 14 point (8) 24VDC In, (6) Relay Out, AC Power Supply (includes IC200CBL501)

IC752CBT063RR Datapanel 320T CE with Advanced software: Expansion with 2MB. 320x240 1/4 VGA Passive Color w/ 80386SX/40. Analog touch screen with text, bitmaps, bar graphs, real time clock. With 2M & PC/104. With Real Time Trends & Host Communications.

MTR-1N42-H-E-A-E-0RR Stepping Motor Nema42 Encoder

ZA06B-0141-B175#7008 AC12/2000 servo motor with brake and 32k serial encoder

20BD5P0A3AYNAND0 PowerFlex 700 AC Drive 5 A at 3 Hp 20B

20G14NC104JA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-E027 PowerFlex 520 18.5kW (25Hp) Power Module

771BSS47410 Quantum CONCEPT XL 版注册软件,10用户

FRN11E1S-2J 17KVA 47A 11KW 3相AC220V/50Hz/60Hz

1492-J3-G 2.5 square mm Standard Terminal Block

1492-SPM3D060-N MCB Supplementary Protector 6 A

软启动器 3RW40382BB05

SIMATIC HMI 系列面板 6AV2123-2MB03-0AX0 KTP1200 Basic PN 12 寸触摸 + 按键

150-SF2R SMC-50 Frame C 24V DC Replacement Fan

1738-CBL3M25DS ArmorPoint Accessory

1783-ZMS8T8E2TGN ArmorStratix 5700 18 port managed switch

193-KA80 0.55-.80 A IEC Bimetallic Overload Relay

20-750-PBAY-INS-2 POWERFLEX 750 KIT,INSULATOR,2 BAR

2090-CPWM7DF-16AF40 MP-Series 40m Length Power Cable

20AB028C0AYNANC0 PowerFlex 70 AC Drive 28 A at 10 Hp 20A

GA647IFPLDVUNLMT GCA iFIX Plus SCADA Unlmt Dev

GP647IFCLNTSRO001 GCP iFIX iClientTS Read Only 5 PK Runtime Version

IC600BF816RR Type T Thermocouple Input Module (8 points)

IC647HSTCC500KM Calculation Collector for Historian - Standard Server 500,000 Points (M4 Key)

IC647TDV075 CIMPLICITY HMI Server 75 I/O Development & Runtime System

IC693MDL931 Relay Output, 8 Amp Form B/C contacts, Isolated in groups of 4

IC756LDV001J-925 DataViews Development on Intel Linux/Red Hat 32 bit, Addt'l User, Japanese v9.25

Pico Controllers 1760-NDM MEMBRANE PROTECT DISPLAY

PLC-5/1771 System 1771-OND 24VAC OUTPUT MODULE, 16 OUTPUTS

Distributed I/O 1791-24BR BLOCK I/O, 24V DC, 32 POINT MODULE

Communications 1786-TPR CONTROLNET T-TAP/RIGHT ANGLE

Operator Interface 9701-VWSTMFRE RSVIEW STUDIO FOR MACHINE EDITION (FRENCH)

Support 9701-VWSTMS SUPT RENEWAL CONTRACT FOR 9701VWSTMENE

Support 9324-RL0300ENR SUPT REINSTATEMENT CONTRACT FOR 9324RL0300EN

EtherNet/IP Products 1747-L553 SLC 5/05 CONTROLLER

RSI Software Products 9301-2SE3500DEU1 RSVIEW32 RUNTIME 32K-100K UPGRADE IN-SUPT (DE)

RSI Software Products 9356-PRO2450U5 UPGRADE: IN-SUPT: RSSQL PROF.150 TO PROF.32000 TAG

Motion Control F-6300-R-H00AA BRUSHLESS MOTOR/ENCODER

44A728335-002 Test Only - PLC

IC200ALG260 ANALOG INPUT 12 BIT VOLTAGE/CURRENT 8CH

IC693MDL740LT 12/24 Vdc Output, 0.5 Amp, Positive Logic (16 Points) (LT)

TRM-21006670 Connector, 4.3 Amp, 115/230V S2K AC Power

VMEM-IMOD VisualMEM MEMPort Input Module. Requires (1) Gateway module per PC.

20BD022A0AYYADD1 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FC060JA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D022N103 PowerFlex 400- 11 kW (15 HP) AC Drive

140CRP93100C Quantum RIO 处理器接口, S908 Head, 单电缆, CC

285-BRC25-M4 Source Brake Cordset Cable

继电器输出:一常开/闭250VAC 5A,电压输入,带键锁. 面板尺寸:48*48.mm

1492-SPM1D250-N MCB Supplementary Protector 25 A

通用型变频器 6SE6 440-2UD37-5FB1 "75 KW,350 x 850 x 320"

电机启动器 3VU13401TH00

150-C85NBD SMC-3 85A Smart Motor Controller

1692-ZR1111 24 V DC Electronic Circuit Protection

1771-IGD 1771 16 Point Digital Input Module

193-EC3GG E3 Plus 42-210 A Overload Relay

198-PL26G ModCenter IEC Pilot Light

2090-CPWM4DF-14AF04 MP-Series 4 m Length Power Cable

2094-BC01-MP5-M Kinetix 6200/6500 Integrated Module

DEMOCD00003 Proficy RTIP DEMO CD

GFK-0685 Series 90 Programmable Controller Flow Computer User's Manual

IC200UMM102 VersaMax MicroMotion, 2 independent axis, 120/240VAC powered. Compatible with VersaMax Micro 20/40/64 and QuickPanel Control or standalone. Requires firmware 3.8 and above for Micro20/40/64.

IC647AQS001 PA Quality Server

IC647PME025 Proficy Change Management Server Machine Edition Version - 25 Concurrent Users

IC693CMM302RR Communication Module, Genius (1 Kbyte) GCM+

IC754VBF08CTD View Loaded 8In Color TFT Touch DC Blank

MSI-AUTOLINE-43 L<(>&<)>W Autoline Interface-ver 4.3

SLC/1746 System 1746-F2 FUSE FOR CATALOG NUMBER 1746-P2 POWER SUPPLY

Distributed I/O 1734-IM2 230 VAC 2 CHANNEL INPUT MODULE

Application-specific products 1803-EEM11 EEM, 16 PULSES,24V DC,8 ANALOG,4 TO 20 MA

Operator Interface 2711-T10G20 PV1000 GRAYSCALE TOUCH, ENET & RS232 PRINT

Support 9301-RSVGEMENR SUPT REINSTATEMENT CONTRACT FOR 9301RSVGEMEN

Support 9381-PP10KENS SUPT RENEWAL CONTRACT FOR 9381PP10KEN

DeviceNet Products 1790D-TN4V0 DNET LDX, 4 INPUT VOLTAGE ANALOG BSE, TERM BLOCK

RSI Software Products 9301-2SE330ZHU2R RSVIEW32 RUNTIME 150-1500 UPGRADE OUT-SUPT (ZH)

RSI Software Products 9358-PBNTK60ENE RSBATCH NT FOR PROCESSLOGIX BACK-UP KEY 60 UNITS

Motion Control MPL-B680D-SJ22AA MOTOR,SERVO,60.0NM,2000RPM,SINGL,460V

Silver Series

HE200TIM100-02 GPS time server for SER300, for time synchronization between separate racks or locations

IC646NUU000 Transaction Processing Fee

PC752DVM104 Scanner module to be a master of DeviceNet network

ST-2514 STXi output module 4 points, Negative Logic, Diagnostics, 24VDC/ 2A

20BC085A3AYNANC0 PowerFlex 700 AC Drive 85 A 45 kW 20B

20F14NC140JN0NNNNN PowerFlex 753 AC Packaged Drive

22A-B012F104 PowerFlex 4 2.2 kW (3 Hp) AC Drive

TSXMRPC003MC Quantum Unity V2 PCMCIA存储扩展卡（SRAM)，程序存储192-3072K，数据存储2880-0K，带涂敷涂层

284-PWRM22G-M3 ArmorConnect 3PH Pwr Media Shld Mtr Cbl

CJ1G-CPU44 CPU单元I/O点数1280，30K程序容量，最多三个扩展机架。

1492-RCDA4D80 Residual Current Device 80 A

6ES7972-0AA01-0XA0 PROFIBUS 中继器，RS485，达到 12Mbit/s

变送器 3RS20 40-1GW50

1497-M-AXSX-0-N Control Circuit Transformer

1606-XLE480FP-D XLE 10 Amp Power Supply

1764-28BXB MicroLogix 1500 28 Point Controller

188-K3D500 Miniature Circuit Breaker 50 A

194L-HE4I-178I 194E Type 1 Handle, IEC Legend, OFF - ON

2090-CPBM7DF-08AF04 4 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S04 Kinetix Drives 4m Standard Cable

BC647UNV00RM University Program Renewal Key (M4)

GC647PSF300 Global Care for Proficy Process Systems 3000 I/O with iFIX

IC200NDR001 10 point PLC,(6) 24VDC In, (4) Relay Out, 24VDC Power Supply

IC646PPD364 PA-30 with 364 CPU - DC

IC647NCA150 CIMPLICITY Change Approval for 150 Point Server

IC690ACC903 RS-485 Port Isolator

IC697VDR151 Discontinued. Replacement is Embedded VMIVME-2210-100 Not UL Approved. Contact GE Embedded for more details.

IC800STI105D2RR 5A, 115V, DeviceNet S2K Stepper Controller

SLC/1746 System 1747-ACNR15 CONTROLNET ADAPTER, REDUNDANT

Industrial Computers 6181P-15TPXPHSS VERSAVIEW STAINLESS STEEL DISPLAY COMPUTER 15-INCH

Application-specific products 9358-PBNT30ENE RSBATCH NT FOR PROCESSLOGIX 30 UNITS

Operator Interface 2711-K5A1L3 PV550 MONOCHROME KEY, RIO & RS232 PRINT