RobotWorks 4 is a major change in perception and in scope from previous versions.
There are robot users and CAD users out there in the industry, but not enough of both.
RobotWorks was rebuilt from the ground up with new purpose in mind, to enable all users to find their comfortable environment without asking them to learn so much, until they want and ready.

Robot users will find now many more "robot-like" functions and behavior they are familiar with, with less CAD interaction.
CAD users will now find RobotWorks as an extension to their CAD environment, with many robotics issues "under the hood".
New users from any field can run RobotWorks with very little knowledge, as RobotWorks is ready to run using default values and settings. It comes with a popular robot model and some ready-made robot tools.
As before, and with even greater functionality, RobotWorks enables crating robot jobs without even having a particular robot in mind.

It is very important to note, that RobotWorks is NOT robot-specific. Any path done with one robot may be done with another.

Following are the main RobotWorks 4 new features (not in any particular order or importance). Understanding "what's new" requires some prior knowledge of RobotWorks from previous versions.

Throughout this manual, new and significant changes from previous versions are noted with this sign. This will be useful for existing and experienced users who are "already used" to do things in a certain way.
 

1. Internal Kinematics

RobotWorks 4 contains a full forward and inverse Kinematics package. It is no longer dependent upon SOLIDWORKS solver for proper arm configuration and joint values.
Now, immediately after Create, each path point has a new attribute, either it's:

The robot can now be selected from a list, with immediate sizing verification. Each click on a robot name shows the selected robot and limits, and each path point appears in appropriate color for instant verification.
The internal Kinematics function will calculate all the path points and enable perfect match for a robot.
Non-experts can rely on RobotWorks to assure correct operation. Green light means ?go ahead, the path is ready?.
Unlike before, there is no need to run to get joint angles. Once the green light is on, a robot file may be saved immediately (perfect for long jobs with small changes).

2. Robot Selection

It is not required anymore to have any robot in the application assembly in order to produce a path. The minimum components are a part and a tool. The robot is only selected after the path can be verified for reach.
In addition to be able to see which points are reachable, and before inserting a robot, the robot 3D envelope can be inserted and observed, as a transparent sphere representing the robot reach. In addition, the robot picture and limits can be seen for verification before the robot is added.

All the robots are supplied in the new RobotWorks 4 format, in a special folder. (They may be used with older versions too).

Once a robot is selected it may be inserted automatically into the assembly. In this case the original robot model (as supplied with RobotWorks) will remain intact and may be used again for other assemblies.

In addition to selecting robots it is now possible to set a preferred Arm Configuration, to be used by RobotWorks Kinematics during the path creation.
 

During the path motion, if the arm configuration may switch to the "other" solution, RobotWorks will "look backwards" and apply the correct configuration, thus avoiding "config change" errors later at the robot.

RobotWorks supports the idea of the main three configuration cases Above/Below, Up/Down and Flip/No Flip. Although different robot controllers call these cases by different names, they still function the same.

3. Automatic Tool Mounting

Tools (and parts in Part Mode) can now be "mounted" automatically on the robot flange.

When robots are changed the tool will remain in the assembly and be mounted automatically on the newly inserted robot.

A tool may now be built (or imported) in any way or orientation. Each tool now needs a mounting flange just like a real tool. Additional markers on the tool at the flange will make it understood to RobotWorks.
 

RobotWorks now includes a utility that creates all these attributes automatically.

All the tools used in RobotWorks 4 will have identical interface to the flange, so switching robots and tools will be simple and almost automatic.
The process of mounting a tool/part to the robot creates mates in the assembly automatically. These mates are different than the ones used in previous versions.

4. Job Management

It is now possible to create, save and load different jobs per one assembly. It is also possible to load a RobotWorks job first, as it will load the appropriate assembly used with it.

A job preview is now available, showing the important details of a job and enables selecting the correct one.

5. Points Reduction

New control functions reduces the number of points automatically, based on the curvature of the path. By default, straight lines will get only end points, true arcs will get end points and one mid point and any 3D curve will be examined automatically and be converted to a set of straight segments, based on user-defined distance in 3D between each point and the original curve.
This picture shows a path with 183 points, evenly spaced every 10 mm.

This picture shows the same path after points reduction, having only 44 points, based on a maximum of 1 mm deviation from the original curve.

This operation may be repeated as necessary.

6. Process vs. Simulation Points

A new approach is now taken to differentiate between "what you see" (on the screen during simulation) and "what you get" (at the robot).
Robots will move between points in straight line even when given only two points. However, RobotWorks must run along many mid-points just to make the simulation look realistic.
Therefore, the path points are now having two types, those used for simulation and collision detection (many points in fine pitch) called Motion points (shown here as yellow lines), and those used to be exported to the robot (called Process points, shown here as blue squares).

The division follows the Reduce Points concept. For example, a square will only send 4 points to the robot, but may have hundreds of points for the realistic simulation and ability to check collision between points.
In addition, along true arcs or circles, although few points will be sent to the robot, the motion on the screen will still be shown circular.
All the points will be saved and loaded, and their duty may be switched by the user at any point.

7. Points Access in the Path Manager

Another concept change is the new Path Manager, which now shows and enable access to individual path points.
Each lead will now show its points, numbered sequentially. Right-click on a point enables point operation, such as:

Goto (makes the tool jump to the point)
Reset point (resets all point modifications)

Set to Motion Only (sets point as available for the simulation only)

Process Type (gives the user the option to add attributes to this point)

Approach/Depart (enables approach or depart to each point at user-defined height along Tool Z)

Copy / Paste (enables transferring point settings to another point or group of points)

Events can be added and edited

Properties of the point can be observed.

Each point will have a graphical display showing its status so it will be easy to see modified point (like P16 shown) or points with special status.

The menu of options per point will reflect the current point status.

8. Points Process Types

In an effort to enable better integration between RobotWorks and actual robot jobs, RobotWorks now assigns a Process Type code to points, based upon what they actually do in the robot application. The simplest form of this definition was always internal in RobotWorks, like the difference between point in air to point on part. This enabled RobotWorks, for example, to write different speed values to points, or assign the correct motion command J or L to the move, based on what the point is on.

This idea is now being expanded significantly, and at the same time is open for the user to interact with. RobotWorks now exposes this information to the Convert grid and gives the user a way to view and modify it to better suit the application.

All RobotWorks' post-processors now take their input from the grid without "internal" decision what is "right" or "wrong". Users now have much better control on what the robot will receive.

The assigned process types are as follows:

1. Point on lead - The point is on a part, in middle of a process (e.g. during welding, gluing etc.)
2. Point in air - On spaces, Pose points or on its way to or from other process points of any type.
3. Begin Process - The first process point on a lead (where usually a process is switched on, e.g. ARC ON)
4. End Process - The last process point on lead (where usually a process is switched off, e.g. ARC OFF)

5. Approach Point - A point before the first process point on lead (sometimes used to start process in air)
6. Depart Point - A point after the last process point on lead (sometimes used to stop process in air)

Process types are assigned automatically by RobotWorks to every process point (a point exported to the robot), but the user can change the type easily at any point.

9. TCP Settings

TCP is a robotics concept (Tool Center Point) and is now embedded in RobotWorks too, as an effort to make things more like in robotics and less like in CAD.

Prior to this version, RobotWorks used to move the tool /part based upon its origin point as set in SOLIDWORKS. Tools had to be built in one special way, with their TCP at the origin and also oriented in special way (Z out etc.).

The tool now works just like in a robot - if no tool is selected, the point of reference is the flange center.

Setting the TCP in RobotWorks is now identical to the way it's done on the robot, and the same numbers may be entered (e.g. if a tool was defined at the robot using a teach pendant).

TCP settings may be saved and loaded, so the same tool may be used with several settings to check "what if" easily.
 

The tool now may leave behind a visible Footprints in user-defined color and width, to enable seeing where the robot has already been.

10. Save and Load Points and Paths

In previous versions RobotWorks saved only modified points, and upon loading it reconstructed the Order of selections and Created new points based on the selections.
In this version, all the points are saved (simulation and process points) and loaded. If the path can be reconstructed, the Script will load as before and all the original points will be re-instated.
A built-in internal converter will load RW3 files and upgrade their data automatically. If leads will not match the current assembly, the available points will still be loaded (as External type) and become regular points.
There will be a wizard assisting the users to upgrade some parts in the assembly in order for them to be compatible with RobotWorks 4.

11. Instant Update upon Point Modifications
 

All point modifications except pitch change will act transparently and immediately without Create again. That will include approach / depart, takeoff / landing, offsets etc.

motion within an envelope of about 2 x 2 x 2 meters, with accuracy of few mm / degrees.

Records the motion (location and orientation) and the finger activity (trigger). Optionally records analog finger position.

Different tips / tools may be mounted on the pod (the movable handle).