RobotStudio 2026 doesn't start virtual controller from pack and go and cannot create one from layout either

Been dealing with this all week, and have people looking into it. I want to hear any thoughts about this.

License is active. When I go to open the RSPAG file, I follow the Wizard and have even installed the Add-In for the RobotWare version prior. When I select finish to unpack it, Robot Studio completely closes down after 3 to 5 seconds. No errors! Just closes out completely.

What I have discovered is, there appears to be no virtual controller in the folder therefore it won’t start the virtual controller. I have been able to open the station model, but have no functionality because the virtual controller stays stopped in red.

The integrator also supplied just the virtual controller folder for me to dump into mine. Opened the station file. That opened fine as usual. The controller did “try” to start. But the Controller Status stayed on the state Starting forever. Then I got the error “There was a problem starting the virtual controller. No response from controller.” (hmm you think so?)

I have uninstalled and reinstalled the Add-Ins. I have uninstalled and reinstalled the entire RobotStudio software as well as Arc Weld Power Pac 2. I have confirmed my system requirements on my computer meet or exceed minimum requirements.

My file path destinations look correct.

Also I have tried to create a dummy project cell and still cannot create a virtual controller from layout. It does the same thing. Closes out completely.

This is beyond frustrating.

Let’s hear some thoughts!

2 Likes

Hi…
Were you able to create the station, but the problem lies with the controller? You can create a new controller from the backup and add it to your station.
After creating the new controller, if your goal is to run the simulation, you will need to check the existing connections under Simulation >> Station Logic and recreate them in the new controller.

I’m using RS2024, so the cause might be different, but I’ve encountered similar issues before, and this was the quickest solution.

Good work.

Hello.

To clarify the situation and narrow down the problem, could you try setting up a simple project station with a robot and a virtual controller? If you still experience the same problem, it’s likely due to certain firewall settings that are preventing your computer from creating and starting the virtual controller. To confirm this and if possible you can try to open the RSPAG file on another PC.
BR
Ricki

It was the company security and firewall. Had to have RobotStudio files whitelisted so things could run seamlessly.

I appreciate the help guys! I had a hunch about that early on and when our IT disabled it to test it worked like it should.

Can someone explain to me the difference between project file, station file, and solution file? I’m getting confused on what and how I should save things.

  • Solutions are legacy - they got replaced by Projects in later versions of RS.
  • Projects (and Solutions) contained Station file(s).
  • Back in the day, before version control was added, people used multiple Station files as a primitive version control. This is not useful any longer.

TL:DR - Always work with Projects, unless you’re using a legacy version of RobotStudio that still uses Solutions.

https://tech-community.robotics.abb.com/t/what-are-differences-between-robotstudio-solutions-vs-projects-vs-stations/

Thank yo for the info @Maxim

So this would explain why my solution file is 0KB then?

Right now I have saved pack and go files and station files. When I save a project, it saves it as a station. I just wanted to make sure this was normal.