Modular Design and Analysis of an Intelligent Storage System Based on PLC and Dual‐Stepper Collaborative Control

Abstract

ABSTRACT To address the positioning accuracy and stability requirements of material storage links at the end of flexible automated production lines in the context of manufacturing intelligent transformation, this paper designs an intelligent warehousing system based on S7‐1200 PLC. The technical scheme takes PLC control as the core, integrates 3ND583 and M415B dual stepper drivers to drive a two‐dimensional ball screw mechanism, and combines with a pneumatic pushing system and various sensors. Verified by joint simulation with TIA Portal PLCSIM and WinCC, the system supports manual/automatic mode switching, meeting the low‐noise and high‐stability storage requirements of teaching training and industrial scenarios. The innovation lies in proposing a dual stepper collaborative control algorithm, which realizes multi‐axis synchronous motion control through pulse equivalent matching and speed parameter optimization. Although the system is based on the automation and information technology of Industry 4.0, its modular design, easily expandable configuration monitoring interface, and manual mode that supports manual intervention provide a good technical foundation for the transition to the ‘human‐machine collaboration’ paradigm advocated by Industry 5.0.