ABB PickMaster Twin - PowerPac

Questions and Answers

T
twrightAug 5, 2025
How to troubleshoot bad position accuracy in ABB Robotics?
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  Rhonda GarrettAug 5, 2025
  If you're experiencing bad or varying position accuracy with your ABB Robotics system, begin by verifying the accuracy of the Counts Per Meter calibration, performing this check multiple times. Avoid using drive shaft encoders, as belt slippage between the roller and belt can introduce variability. Inspect the camera calibration; a poor-quality calibration grid will lead to inaccurate calibration results. Check for height differences between the calibration paper and the product. Also, look for parallax errors when identifying high products and ensure the camera is not mounted on the robot frame, as this can cause camera vibrations.
R
Richard MorenoAug 15, 2025
What to do if ABB PickMaster Twin - PowerPac positions are used twice?
- J
  james36Aug 15, 2025
  If positions are being used twice in your ABB Robotics setup, and you're using I/O triggered predefined positions or containers, set the _SyncSeparation filter distance to avoid double and ghost triggers. If vision is used, increase the overlap and position filter. If a robot downstream in an ATC group tries to use an already used item, check the Work Area order in the Position Source.
A
Ashley ChavezAug 25, 2025
What to do if the ABB Robotics camera does not take pictures?
- K
  Kristie BaileyAug 26, 2025
  If the ABB Robotics camera isn't taking pictures, first, check that the trig cable is properly connected. A potential cause is a bad encoder connection or selecting the wrong conveyor in the work area. Also, verify that the camera cable is connected to the correct port, as the issue could stem from a wrong connection or bad reflection.

Summary

Welcome to PickMaster PowerPac

Introduction

Provides an overview of PickMaster Twin, its capabilities for high-speed picking, and customization options for specific needs.

PickMaster PowerPac Terms

Defines key terms and concepts used throughout the manual for understanding picking and placing processes.

Installation

PickMaster Package

Details the software installation packages for PickMaster Twin Client and Host, including their intended use and included software.

System Requirements

Outlines the necessary hardware and software specifications for installing and running PickMaster PowerPac effectively.

PickMaster PowerPac License

Explains the licensing options available for PickMaster PowerPac, including Basic and Premium features, and activation procedures.

Software Installation

Provides guidance on the software installation process, emphasizing safety precautions for personnel working with ABB robots.

Electrical Connection

Illustrates the electrical connections for PickMaster Twin, covering camera, network, and controller interfaces.

Connecting Cameras

Details the procedure for connecting cameras, including power, I/O functions, and validated camera models.

Configuring Networks

Explains how to configure controller and vision networks, including IP addressing and subnet settings.

Setting Up Robot Controller

Guides on setting up the robot controller for PickMaster PowerPac, covering RobotWare, system parameters, and I/O signals.

Navigating PickMaster PowerPac

Main Window

Describes the user interface elements of PickMaster PowerPac, including the ribbon tab, tree view browser, station view, and status view.

Ribbon Tab

Details the functions and configurations available in the PickMaster PowerPac ribbon tab, organized by groups like File, Layout, and Recipe.

Tree View Browser

Explains the tree view browser in PickMaster PowerPac, focusing on the Cell tab which displays application hardware objects.

Working with PickMaster PowerPac

Setting Up Solution and Recipe in Virtual Runtime (VRT)

Guides on setting up solutions and recipes within the virtual runtime environment, covering creation and templates.

Configuration in Real Runtime (RRT)

Details the process of configuring PickMaster PowerPac in real runtime mode, including switching to RRT and connecting to controllers.

Calibrating Camera

Explains the camera calibration process, including checkerboard and multi-view methods, and prerequisites for accurate results.

Starting Production

Describes how to start and manage the production process in PickMaster PowerPac, covering emulation and status monitoring.

Managing the Robot in Production

Covers managing robot states, stopping/resuming operations, and handling emergency stops during production.

Ghost Picking

Explains the ghost picking flow, used for dry cycle simulation before production, where robots pick empty objects.

Production Examples

Example: One Pick Work Area and One Place Work Area

Demonstrates setting up a solution with one robot, two linear conveyors, picking items from one and placing them into containers on the second.

Example: One Pick from Indexed Work Area and One Place Work Area

Illustrates changing a solution to use an indexed work area for picking and a linear conveyor for placing items.

RAPID Reference

Instructions

Details core RAPID instructions for item handling, including acknowledging targets and flushing item sources.

GetItmTgt - Get the Next Item Target

Explains the GetItmTgt instruction for retrieving the next available item target from a source queue.

RAPID Program

Describes default RAPID programs, their customization, execution, work areas, and movements.

Routines

Lists and describes public routines in PickMaster template programs, covering main, safety, and pick/place operations.

Troubleshooting

Safety During Troubleshooting

Outlines critical safety considerations and dangers when performing troubleshooting procedures on powered equipment.

Fault Symptoms or Errors

Details common faults and errors, including specific warnings and their probable causes and verification actions.

The Camera Does Not Take Pictures

Addresses issues where the camera fails to capture images, listing potential causes like connection or trigger problems.

Robot Does Not Move

Troubleshoots scenarios where the camera functions but the robot fails to move, checking strobe, distribution, and I/O signals.

Error Codes

Provides a comprehensive list of common error codes encountered in PickMaster PowerPac, with their types and descriptions.

Spare Parts

Camera Parts

Lists spare part numbers and descriptions for camera components, including Cognex camera kits.

USB Dongle Parts

Details spare part numbers for USB dongles (small, large, SIM) used for software licensing and functionality.

GigE Network Card Parts

Lists spare part numbers and descriptions for GigE network cards required for vision system communication.

Circuit Diagram

Circuit Diagrams

Provides article numbers for accessing circuit diagrams for various controllers and RobotWare options via the myABB portal.

ABB PickMaster Twin - PowerPac Specifications

General

Category	Robotics
Communication	Ethernet
Compatibility	ABB robots
Integration	Seamless integration with ABB robot controllers
User Interface	Graphical user interface