ABB PickMaster Twin - PowerPac Instructions for use

ROBOTICS
Application manual
PickMaster®Twin - PowerPac

Trace back information:
Workspace Main version a394
Checked in 2021-03-25
Skribenta version 5.4.005

Application manual
PickMaster®Twin - PowerPac
IRC5 and OmniCore
Document ID: 3HAC064218-001
Revision: B
© Copyright 2021 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damage to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2021 ABB. All rights reserved.
Specifications subject to change without notice.

Table of contents
9Overview of this manual ...................................................................................................................
131 Welcome to PickMaster PowerPac
131.1 Introduction ......................................................................................................
151.2 PickMaster PowerPac terms ................................................................................
172 Installation
172.1 PickMaster package ..........................................................................................
192.2 System requirements .........................................................................................
192.2.1 Hardware and software requirements ..........................................................
202.2.2 Ethernet switch .......................................................................................
212.2.3 Vision system .........................................................................................
222.2.4 Camera requirements ..............................................................................
252.3 PickMaster PowerPac license ..............................................................................
282.4 PickMaster time synchronization service ...............................................................
292.5 Software installation ..........................................................................................
302.5.1 Installing RobotStudio ..............................................................................
312.5.2 Installing PickMaster Twin Client ................................................................
342.6 Electrical connection ..........................................................................................
34
2.6.1 PickMaster®Twin Hardware connection illustration ......................................
352.6.2 Connecting cameras ................................................................................
372.6.3 Connecting I/O signals .............................................................................
392.6.4 Configuring networks ...............................................................................
422.6.5 Setting up robot controller ........................................................................
432.6.6 Optional robot and process configuration ....................................................
442.6.7 Six axes robot configuration ......................................................................
453 Navigating PickMaster PowerPac
453.1 Start page ........................................................................................................
463.2 Main window ....................................................................................................
473.3 Ribbon tab .......................................................................................................
473.3.1 Introduction ............................................................................................
563.4 Tree view browser .............................................................................................
563.4.1 Cell .......................................................................................................
683.5 Status view ......................................................................................................
694 Working with PickMaster PowerPac
694.1 Overview .........................................................................................................
714.2 Setting up Solution and Recipe in virtual Runtime (VRT) ...........................................
714.2.1 Creating Solution ....................................................................................
754.2.2 Adding Controller ....................................................................................
814.2.3 Adding Gripper .......................................................................................
854.2.4 Adding Conveyor ....................................................................................
884.2.5 Adding Sensor ........................................................................................
934.2.6 Adding work area ....................................................................................
1014.2.7 Adding Item ...........................................................................................
1054.2.8 Adding Container ....................................................................................
1194.2.9 Adding Recipe ........................................................................................
1354.2.10 Adding Flow ...........................................................................................
1574.2.11 Calibration .............................................................................................
1594.2.12 Simulation .............................................................................................
1714.3 Configuration in real Runtime (RRT) .....................................................................
1714.3.1 Switching to real Runtime .........................................................................
1814.3.2 Configuring camera .................................................................................
1854.3.3 Calibrating robot .....................................................................................
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Table of contents

1864.3.4 Calibrating linear conveyor .......................................................................
1874.3.4.1 Defining the parameter Counts Per Meter (DSQC 377) ........................
1894.3.4.2 Defining the parameter Counts Per Meter (DSQC 2000) ......................
1914.3.4.3 Defining the base frame (IRC5) ......................................................
1944.3.4.4 Defining the base frame (OmniCore) ...............................................
2074.3.5 Calibrating circular conveyor .....................................................................
2084.3.5.1 Defining the parameter Counts Per Meter (DSQC 377) ........................
2104.3.5.2 Defining the parameter Counts Per Meter (DSQC 2000) ......................
2124.3.5.3 Defining the base frame (IRC5) ......................................................
2164.3.5.4 Type configuration for circular conveyor ..........................................
2184.3.6 Calibrating indexed work area ...................................................................
2324.3.7 Verifying conveyor calibrations ..................................................................
2344.3.8 Calibrating camera ..................................................................................
2404.3.8.1 Showing live images ....................................................................
2414.3.8.2 Detailed vision information ............................................................
2444.3.8.3 The image windows .....................................................................
2454.3.9 Adding vision model ................................................................................
2454.3.9.1 Vision modeling ..........................................................................
2464.3.9.2 Configuring a geometric model with PatMax .....................................
2574.3.9.3 Configuring blob models ...............................................................
2644.3.9.4 Configuring inspection models .......................................................
2834.3.10 Starting production ..................................................................................
2874.3.11 Managing the robot in production ...............................................................
2894.4 Using color vision ..............................................................................................
2974.5 Ghost Picking ...................................................................................................
3075 Production examples
3075.1 Example: One pick work area and one place work area ............................................
3295.2 Example: One pick from indexed work area and one place work area ..........................
3365.3 Example: Mixing one pick work area and two place work areas ..................................
3616 RAPID reference
3616.1 Instructions ......................................................................................................
3616.1.1 AckItmTgt - Acknowledge an item target ......................................................
3636.1.2 FlushItmSrc - Flush an item source .............................................................
3646.1.3 GetItmTgt - Get the next item target ............................................................
3706.1.4 NextItmTgtType - Get the type of the next item target .....................................
3726.1.5 QStartItmSrc - Start queue in item source ....................................................
3736.1.6 QStopItmSrc - Stop queue in item source ....................................................
3746.1.7 ResetFlowCount - Reset flow counter .........................................................
3756.1.8 ResetMaxUsageTime - Reset max measured usage time ................................
3766.1.9 UseReachableTargets - Use reachable targets ..............................................
3796.2 Functions ........................................................................................................
3796.2.1 GetMaxUsageTime - Get max measured usage time ......................................
3806.2.2 GetQueueLevel - Get queue level ...............................................................
3826.2.3 GetQueueTopLevel - Get queue top level ....................................................
3836.2.4 GetFlowCount - Get number of passed items ...............................................
3846.3 Data types .......................................................................................................
3846.3.1 itmtgt - Item target data ............................................................................
3876.3.2 selectiondata - Selection data ....................................................................
3906.3.3 sortdata - Sort data ..................................................................................
3916.4 RAPID program ................................................................................................
3916.4.1 RAPID programs .....................................................................................
3966.4.2 Variables ...............................................................................................
3996.4.3 Routines ................................................................................................
4036.4.4 Service routines ......................................................................................
4046.5 Program examples ............................................................................................
4046.5.1 Example: Mixing one pick work area and two place work areas ........................
4056.5.2 Example: Mixing two pick work areas and one place work area ........................
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Table of contents

4066.5.3 Example: Mixing with one pick and one place work area .................................
4076.5.4 Example: Double pick single place .............................................................
4106.5.5 Example: Placing a predefined pattern on indexed work area ..........................
4126.5.6 Example: Selecting item depending on clearance zone ..................................
4156.5.7 Example: Sorting in negative y-direction ......................................................
4186.5.8 Example: Indexed work area with predefined position ....................................
4196.5.9 Example: Automatically generating new positions to indexed work area ............
4217 Troubleshooting
4217.1 Introduction to troubleshooting ............................................................................
4227.2 Safety during troubleshooting ..............................................................................
4237.3 Administering the log .........................................................................................
4247.4 Fault symptoms or errors ....................................................................................
4247.4.1 Warnings 4326 - 4329 ..............................................................................
4287.4.2 The camera does not take pictures .............................................................
4297.4.3 Robot does not move ...............................................................................
4307.4.4 Bad or varying position accuracy ...............................................................
4317.4.5 Positions are used twice ...........................................................................
4327.4.6 Problem with camera resolution in PickMaster ..............................................
4337.5 Error codes ......................................................................................................
4458 Spare parts
4479 Circuit diagram
4479.1 Circuit diagrams ................................................................................................
449Index
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Overview of this manual
About this manual
This manual contains instructions for installation, configuration, and operation of
PickMaster PowerPac.
Note
All safety information for working with the controller is described in the product
manual for the controller.
Usage
This manual should be used during installation, configuration, and maintenance
of a PickMaster system.
PickMaster PowerPac is intended for use as an engineering tool on a portable
laptop PC for offline use and online connection to a host computer in the installation
for commissioning purposes. PickMaster PowerPac is not intended for use on the
host computer under production conditions.
Who should read this manual?
This manual is intended for:
• Installation personnel
• Programmers
• Integrators
• Operators
Prerequisites
Any maintenance/repair/installation personnel working with an ABB robot must be
trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Cybersecurity
This product is designed to be connected to and to communicate information and
data via a network interface. It is your sole responsibility to provide, and
continuously ensure, a secure connection between the product and to your network
or any other network (as the case may be).
You shall establish and maintain any appropriate measures (such as, but not limited
to, the installation of firewalls, application of authentication measures, encryption
of data, installation of anti-virus programs, etc) to protect the product, the network,
its system and the interface against any kind of security breaches, unauthorized
access, interference, intrusion, leakage and/or theft of data or information. ABB
Ltd and its entities are not liable for damage and/or loss related to such security
breaches, any unauthorized access, interference, intrusion, leakage and/or theft
of data or information.
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© Copyright 2021 ABB. All rights reserved.
Overview of this manual

References
Tip
All documents can be found via myABB Business Portal, www.abb.com/myABB.
OmniCore
Document IDReference
3HAC073650-001Product specification - PickMaster Twin
3HAC024480-020Circuit diagram - PickMaster Twin
3HAC069977-001Application manual - PickMaster Twin - Operator
3HAC031045-001Safety manual for robot - Manipulator and IRC5 or OmniCore
controller i
3HAC060860-001Product manual - OmniCore C30
3HAC065036-001Operating manual - OmniCore
3HAC066554-001Application manual - Controller software OmniCore
3HAC042927-001Technical reference manual - Lubrication in gearboxes
3HAC065041-001Technical reference manual - System parameters
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
External references
DescriptionReference
For configuring camera networks.Cognex Ethernet Camera Tool
For camera communication.Gigabit Ethernet Performance Driver
Information about Basler Ace Gigabit Ether-
net cameras and the switch for Gigabit Ether-
net cameras.
aca1440-73gc
Information about Basler Scout Gigabit Eth-
ernet cameras and the switch for Gigabit
Ethernet cameras.
sca1300-32gc
Detailed information about PC requirements
for the vision system.
CognexPCConfigGuide
Revisions
DescriptionRevision
First edition.A
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Overview of this manual
Continued

DescriptionRevision
Published in release 21A. The following updates are made in this re-
vision:
• Added information on supporting OmniCore controller.
• Added description of accounts management and http protocol
safety issue.
• Minor corrections.
• Added a note on refreshing the controller system list when
adding a controller in PickMaster PowerPac.
• Added notes for real Runtime connection.
• Added description for new time sync service.
• Added note for RW7.2 about the firewall settings on WAN.
• Updated Job Tab option to Recipe.
• Added a note that the PickMaster 3 and PickMaster Twin are
not recommended to be installed on a same PC.
•Updated the operation of editing users in PickMaster PowerPac.
• Updated the definition of Adjustment speed in section Six axes
robot configuration on page 44.
B
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1 Welcome to PickMaster PowerPac
1.1 Introduction
About PickMaster®Twin
PickMaster® Twin is an application product designed for vision based high speed
picking of random flow products on the fly. PickMaster® Twin supports ease-of
use configuration, simulation and operation of a big variation of smaller or larger
line layouts composed of a multitude of robots, cameras, conveyors and fixed work
areas. It comprises all steps in the life cycle of a picking installation from proposal,
engineering, commissioning, operation to maintenance and support.
PickMaster PowerPac can be customized for some of the following special needs:
• With the integrated vision it can be used for full random operation on a
continuously moving conveyors and for absolute accurate positioning on
indexed feeders or trays.
• Without vision recognition it can be used as a tool for the efficient production
with guided product flows on multiple conveyors.
• For efficient quality inspection and product categorization alone or together
with the position recognition.
PickMaster® Twin is a modular product for controlling ABB robots in picking
applications through the robot controller. It is a configurable to perform pick and
place operations of items. A vision system is used to find randomly placed items
on conveying belts. PickMaster PowerPac is the engineering software aimed at
configuring and validating the application in offline simulation with a virtual system
and in online mode directly connected to the real installation. It uses comprehensive
graphical interfaces to configure powerful applications, where it can control multiple
robots picking and placing sensor-detected items on different conveying belts.
xx1900001745
PickMaster Twin comprises the following modules:
PickMaster®PowerPac
Ease of Use software for offline and online configuration and commissioning in a
visual 3D environment, powered by RobotStudio™.
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© Copyright 2021 ABB. All rights reserved.
1 Welcome to PickMaster PowerPac
1.1 Introduction

PickMaster®Operator
State-of-the art user interface for operating PickMaster on the shop floor, built on
ABB’s Ability™ Zenon data management software.
PickMaster®Runtime
Efficient runtime operation software for orchestrating the coordination of the
packaging process for a multitude of robots and conveyors including integrated
vision software for precise robot guidance and quality inspection.
• Virtual Runtime: running the PickMaster process in a simulated virtual
environment on a client system connected to virtual robot controllers.
• Real Runtime: running the PickMaster process in the real production
installation on the host computer.
The following illustration is showing an installation example with 10 robots, 4
cameras and 3 conveyors.
Robots & Robot Controllers
Cameras
Win10 IoT
PickMaster RT
Operator
Zenon
CTM
Multi touch
operation
panel
Win10
PowerPac
RobotStudio
PCIE
NIC
board
GigE
Conveyors
Encoders
Ethernet
Modbus
Profinet
…
Cell/Line
PLC
xx1900001746
Note
PickMaster® Twin is delivered with different hardware configurations. For more
information, see Product specification - PickMaster Twin.
Note
Http protocol is uesd between PickMaster®PowerPac/PickMaster®Operator
and PickMaster®Runtime. This could be unsafe if the user has specific safety
rules. Please take necessary measurements to protect your information.
About PickMaster PowerPac
This manual describes how to install and use PickMaster PowerPac as the
engineering software in two modes:
• Configuring and validating the application in offline simulation with a virtual
system.
• Commissioning in online mode directly connected to the real installation.
This manual also describes the components of the real system, their installation,
configuration and calibration.
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1 Welcome to PickMaster PowerPac
1.1 Introduction
Continued

1.2 PickMaster PowerPac terms
About these terms
Some words have a specific meaning when used in this manual. Definitions of
these words in this manual are listed below. Some of the terms are put in their
context when describing a picking and placing process.
Term list
Words that have italic font style in the definition column are included in the term
list and have their own definitions.
DefinitionTerm
The market name of PickMaster PC software that is used for
configuration and simulation.
PickMaster PowerPac
The market name of PickMaster Tablet software that is used
for configuration and simulation.
PickMaster Operator
The core engine that does all the calculation of virtual pick and
place operation.
PickMaster Virtual Runtime
The core engine that does all the calculation of pick and place
operation.
PickMaster Runtime
It's also called as Runtime.
The installation package which contains PickMaster PowerPac,
PickMaster Virtual Runtime and PickMaster Runtime.
PickMaster Twin Client
The installation package which contains PickMaster Operator
and PickMaster Runtime.
PickMaster Twin Host
A defined picking and placing areas for the robots.Work area
A conveyor that is in a circular type.Circular Conveyor
The generic term for a specific object to be picked or placed
in a PickMaster PowerPac application.
Item
Defines how to generate item positions and which work area
to send them to.
Item source
Defines which patterns to use and what items to use for each
position in the patterns.
Container
'Project' in PickMaster 3, a collection of parameters with regard
to the process of Pick and Place.
Recipe
An activity of imitating the behavior of real cell or line and dis-
play the activity on screen.
Emulation
A kind of dry run, when production uses virtual item to pick,
thus no real item to pick.
Ghost picking
A kind of simulation process when connected to the virtual ro-
bot.
Offline Simulation
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1 Welcome to PickMaster PowerPac
1.2 PickMaster PowerPac terms

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2 Installation
2.1 PickMaster package
Concepts of using PickMaster Twin
PickMaster PowerPac is designed to be installed on a laptop computer that can
host solutions for many different installations that can be connected for
commissioning, new recipe introduction, maintenance and servicing purposes to
the several physical installations, where each one of those have their own
permanent host computer.
There are two software installation packages: PickMaster Twin Client for the portable
engineering system and PickMaster Twin Host for the permanent factory system.
The Client installation does not require any physical equipment installations. All
physical component installations, configurations and calibrations are doneon the
host system.
PickMaster Twin Client
The installations package for PickMaster Twin offline configuration, simulation and
testing is named as PickMaster Twin Client. It installs the following softwares:
• PickMaster PowerPac
• PickMaster Virtual Runtime
• PickMaster Real Runtime
Note
This package is only intended for engineering and not for the final factory
production installation. The ability to switch to real runtime on the same computer
is only intended for test purposes and it can be used for creating and editing
vision models offline. For this purpose a vision demo dongle can be used.
Software Installation Package
Registered ABB customers can download the latest version of the PickMaster Twin
Client and the user documentation for PickMaster PowerPac from the ABB download
center.
Tip
The download center address is
https://new.abb.com/products/robotics/application-software/pickmaster.
Note
The PickMaster software is available in 64-bit version.
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2 Installation
2.1 PickMaster package

When the PickMaster Twin Client is installed successfully, the user documentation
for PickMaster PowerPac and the calibration papers are available in the installation
folder Documentation.
Note
Any old version of PickMaster PowerPac must be uninstalled before installing a
newer version of PickMaster PowerPac.
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2 Installation
2.1 PickMaster package
Continued

2.2 System requirements
2.2.1 Hardware and software requirements
Hardware requirements
Following are the hardware requirements
• A log on account with administrator rights on the computer.
• CPU: 2.0 GHz or faster processor. Multicore processor is recommended.
• Memory: 3 GB if running Windows 32-bit edition. 8 GB if running Windows
64 bit edition. 16 GB or more if working with heavy CAD models.
• Free disk space: 10+ GB free space, solid state drive (SSD) recommended.
• Graphics card: High-performance, DirectX 11 compatible, gaming graphics
card from any of the leading vendors. For the Advanced lightning mode
Direct3D feature level 10_1 or higher is required.
• Display settings: 1920 x 1080 pixels or higher resolution is recommended.
• Dots per inch (DPI): Only Normal size supported for Integrated Vision.
• Mouse: Three-button mouse
• 3D Mouse (optional): Any 3D mouse from 3DConnexion. See
http://www.3dconnexion.com.
Note
When running the software, close other software that consumes a lot of memory,
otherwise it will affect the software normal use.
CAUTION
If robot movement can be initiated from an external control panel then an
emergency stop must also be available.
Software requirements
Following are the software requirements:
• Windows 10 (64 bit).
• Acrobat reader
• Robotstudio 2020.1 or later
• RobotWare 6.11 or later
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2 Installation
2.2.1 Hardware and software requirements

2.2.2 Ethernet switch
Overview
An Ethernet switch is used to connect the PC with multiple robot controllers. It is
recommended to use an unmanaged industrial switch with a communication speed
of 100 Mbit/s or higher. Switches that implement the 1588 PTP protocol have been
known to interfere with the robot controller communication and should not be used.
20 Application manual - PickMaster® Twin - PowerPac
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2 Installation
2.2.2 Ethernet switch