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KUKA Robot Guide
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iiQWorks.Sim

With iiQWorks.Sim, you can program, test, and optimize KUKA industrial robots and cobots offline – without interrupting ongoing production. The simulation software supports robot simulation, process validation, and virtual commissioning, helping you reduce risk, improve efficiency, and accelerate project implementation.

Virtual reality for real success: More efficient projects with simulation software

iiQWorks.Sim is the ultimate simulation software for anyone working with KUKA robots – from programmers and (virtual) startup technicians to technical sales engineers and project managers. With functions such as fieldbus configuration, I/O mapping, TechPackages and SafeOperations, iiQWorks.Sim offers everything you need. Peripheral components, such as conveyor belts, can be integrated into the 3D scene together with signals such as light barriers. In combination with the iiQKA.OS2 operating system, iiQWorks.Sim accelerates startup processes, enhances efficiency, and gives your production a significant competitive edge.

Digital twins optimize robot simulation

Simulation software makes it possible to precisely model and optimize relevant processes in the area of robot simulation. Use iiQWorks.Sim to create a complete digital twin of your KUKA robot system. This allows you to simulate an exact result for your robot project in advance. The digital twin supports planning new robot cells, expanding and optimizing existing ones, and verifying project feasibility.

Benefit from the advantages of simulation software

  • Planning the setup

    You can plan your automated production system efficiently and tailor to your application.

  • Checking practical suitability

    You can ensure feasibility and optimum cycle times for your robot programs and cell layouts.

  • Offline programming

    You can design and test your processes in advance – and become more efficient than your competitors.

  • Simulating the system

    You can simulate your production including logistics and synchronize online and offline worlds with Roundload.

iiQWorks.Sim: Perfect simulation for optimum robot performance

Manufacturers use simulation software to carry out virtual tests and improve robot programming already before operation. This helps to avoid errors and organize processes efficiently.

Secure your automation virtually

Validate robot cells and production processes early with digital twins and simulation. Our experts help you minimize risks, optimize workflows, and bring automation projects to life faster.
Contact an Expert Request Simulation Services

Modular software: Flexible, scalable and tailored to your needs

With iiQWorks.Sim, you can make use of a flexible and durable modular principle: In terms of modular software architecture, the free tool iiQWorks.Sim Basic can be expanded with iiQWorks.Sim Advanced by add-ons. This allows you to customize the robotic simulation software to your individual needs.

iiQWorks.Sim Basic: The starter package for robot configuration

iiQWorks.Sim Basic is free of charge: Start directly with the configuration of your KUKA robot, benefit from the many options of the basic version of the simulation software – and make your production and internal logistics more efficient! Even with the basic package, you can create a complete configuration of your production as well as 3D PDFs, videos or virtual presentations.

iiQWorks.Sim Advanced: Scale your software according to your needs

With iiQWorks.Sim Advanced, you have access to various add-ons that let you scale the software flexibly and tailor it to your production’s specific needs. The add-ons are available separately, so you only pay for what you truly need. And if your requirements change in the future, you can easily expand your setup with additional add-ons.

iiQWorks.Sim Modeling: Optimize CAD data and create custom models

Refine and simplify imported data or model kinematics with the modeling add-on from iiQWorks.Sim Advanced. Customize your own CAD data and save them in the iiQWorks library. Reduce file sizes and improve the performance with automatic geometry simplification and automatic creation of simple 3D models.

iiQWorks.Sim Connectivity: Connect simulations to PLCs and external systems.

Use the iiQWorks.Sim Connectivity add-on to establish various connections to other systems, for example to a PLC. The connection can be established among other things via OPC-UA, a protocol. Or let your system talk to other software, for example the behavior simulations. They can display the response of components (such sensors) and transfer the information to iiQWorks.Sim using the defined format.

iiQWorks.Sim PathProcesses: Plan and Optimize Path-Based Processes Virtually

Simulate and optimize path-guided applications such as welding, bonding, sealing, or machining as early as the planning phase. Tool paths, process sequences, and cycle times can be verified in advance to reduce risks and speed up commissioning.

iiQWorks.Sim PointProcesses: Simulate and Validate Point-Based Applications

Plan and validate point-based processes such as spot welding and inspection applications in a virtual environment. Verify reachability, process points, and cycle times before programming and commissioning on the real system.

iiQWorks.Sim SurfaceProcesses: Simulate and Optimize Surface Finishing Processes

Plan and optimize robot paths for applications such as painting, coating, polishing, and deburring directly on complex part surfaces. Virtual validation of path coverage and process execution helps improve quality while reducing programming effort.
Optimize production workflows offline with iiQWorks.Sim

FAQ on Robot Simulation and Virtual Commissioning

What is robot simulation?

Robot simulation is the virtual representation of robots, robotic cells, and production processes within a digital simulation environment. Using simulation software, manufacturers can plan, test, and optimize robot motions, reachability, cycle times, and material flow before physical deployment. Simulations often rely on a digital twin that accurately reflects robots, peripheral devices, and process behavior. This allows companies to identify risks early, create robot programs offline, and prepare commissioning activities without disrupting production.
Simulation of automated palletizing applications with seamless switching between online and offline programming

What are the benefits of simulation for project cost, time, and risk reduction?

Robot simulation helps manufacturers reduce project costs, shorten implementation timelines, and minimize risk by validating automation concepts before deployment. Robot programs, production layouts, and process sequences can be tested and optimized in a virtual environment without interrupting production. This allows potential issues to be identified early, reducing costly rework and accelerating commissioning activities.

Key benefits include:

  • Offline programming without production downtime

  • Faster project execution and commissioning

  • Fewer planning errors and less rework

  • Optimized cycle times and production layouts

  • Collision and reachability validation before implementation

  • Improved planning reliability through digital twins

  • Early evaluation of automation concepts

  • Reduced project and operating costs

  • Lower project risk through virtual validation

  • Faster implementation of process changes and system upgrades

Case study: How HASE combines digital twins and welding robots to improve efficiency and planning reliability in furnace manufacturing.

How do I get started with iiQWorks.Sim?

Getting started with iiQWorks.Sim begins with software installation and licensing. Guided workflows help you create your first robot simulations, configure KUKA robots, and build virtual robot cells. Comprehensive video tutorials provide step-by-step guidance, from user interface basics to simulation, offline programming, and virtual commissioning.
Learn the fundamentals of navigating iiQWorks.Sim and move confidently through virtual robot cells and digital twins.

What is the difference between iiQWorks.Sim Basic and Advanced?

iiQWorks.Sim Basic is the free entry-level version that allows users to configure KUKA robots and create simulations, 3D PDFs, videos, and virtual presentations.

iiQWorks.Sim Advanced expands the software with additional capabilities for modeling, system connectivity, and advanced simulation workflows. Companies can tailor the software to their requirements and use only the features needed for their specific applications.

In short:

  • Basic: Free entry-level version for robot configuration and core simulation tasks.
  • Advanced: Scalable professional solution for advanced robot simulation, virtual commissioning, and customized engineering workflows.

iiQWorks.Sim Basic vs. Advanced

Capability Basic Advanced Add-on required?
Initial robot simulation setup ✓ ✓ No
Import CAD data and existing project data ✓ ✓ No
Edit and optimize imported simulation data – ✓ No
3D modeling and layout creation – ✓ No
Simulate specialized manufacturing processes – ✓ No
Path-, point-, and surface-process simulation – ✓ Yes
Offline programming with RCS – ✓ Yes
Virtual Robot Controller (VRC) – ✓ Yes
Connect simulations with machines and peripheral equipment – ✓ Yes
Share and deploy simulations – ✓ No

What CAD formats can be imported into iiQWorks.Sim?

iiQWorks.Sim supports a wide range of industry-standard CAD formats, including STEP, JT, CATIA, SolidWorks, Creo, Siemens NX, Solid Edge, Inventor, and IGES. In addition, users can import 2D drawings (DWG, DXF), point clouds, and other 3D file formats to quickly bring existing systems, machines, and robot cells into the simulation environment.

This makes it easy to create digital twins of existing production assets, enabling faster virtual planning, validation, and optimization of robotic applications and manufacturing processes.

Can I import existing systems and machines into the simulation?

Yes. With iiQWorks.Sim, you can import CAD data from existing systems, machines, and robot cells to create digital twins. This allows you to virtually plan, simulate, and validate layouts, robot movements, reachability, and production processes before physical commissioning. As a result, you can optimize system concepts early, streamline implementation, and reduce effort during deployment.
Learn how to migrate a config.dat file from KSS to iiQKA.OS2 and validate it in iiQWorks.Sim.

How does robot simulation help optimize manufacturing processes?

Robot simulation software such as iiQWorks.Sim enables manufacturers to analyze, test, and optimize production processes before they are implemented on the shop floor. By validating applications in a virtual environment, teams can identify bottlenecks, avoid collisions, improve cycle times, and optimize material flow early in the project lifecycle.

Potential planning and engineering issues can be detected before commissioning, helping reduce startup times, minimize production disruptions, and lower both project and operating costs. The result is greater efficiency, improved planning reliability, and faster deployment of new automation solutions.

Key benefits include:

  • Shorter project and commissioning times
  • Reduced engineering and planning effort
  • Optimized cycle times and equipment utilization
  • Prevention of costly collisions and errors
  • Reduced production downtime
  • Faster implementation of system modifications
  • Increased planning reliability through digital twins
  • Better resource utilization and lower overall costs

How does virtual commissioning work?

During virtual commissioning, robot programs, controllers, and system components are tested and validated in a simulation environment before physical startup. This allows engineers to verify processes, signals, safety functions, and robot motions early in the project lifecycle.

By identifying and resolving issues before deployment, teams can significantly reduce on-site commissioning time, minimize risks, and achieve a smoother startup of automated production systems.

Key benefits include:

  • Early validation of robot programs and system behavior
  • Testing of signals, interfaces, and safety functions
  • Detection and resolution of issues before physical commissioning
  • Reduced commissioning time on site
  • Lower project risk and fewer costly modifications
  • Faster ramp-up of production systems
  • Improved planning reliability and system availability
  • Reduced downtime during startup and changeovers

What is a digital twin in robotics?

A digital twin is a virtual representation of a real robot system or an entire production cell. It accurately models robots, peripheral equipment, processes, and workflows, enabling engineers to plan, test, and optimize automation concepts before any physical equipment is built or modified.

By creating a realistic virtual environment, digital twins provide a reliable foundation for simulation, system validation, and virtual commissioning. This helps reduce risk, improve planning accuracy, and accelerate the deployment of new automation solutions.

Key benefits include:

  • Realistic virtual representation of robot systems and production cells
  • Early validation of layouts, workflows, and automation concepts
  • Improved planning accuracy and decision-making
  • Safer testing without disrupting production
  • Faster optimization of robot programs and processes
  • Reduced commissioning risks and project costs
  • Support for virtual commissioning and system validation
  • Accelerated implementation of new automation projects

How does iiQWorks.Sim create a digital twin of a robotic cell?

With iiQWorks.Sim, CAD data, KUKA robots, and peripheral equipment can be integrated into a single virtual environment to create a digital twin of a robotic cell. This digital representation allows engineers to simulate and validate layouts, robot motions, reachability, and robot programs before physical commissioning.

By testing and optimizing applications in a virtual environment, teams can identify potential issues early, improve planning accuracy, and reduce risks during deployment and startup.

Learn how to synchronize physical robots and digital twins using the Roundload workflow in iiQWorks.Sim.

Can I simulate multiple robots in a single project?

Yes. With iiQWorks.Sim, multiple robots, peripheral devices, and complete production cells can be simulated together in a single virtual environment. This makes it possible to analyze interactions between robots, coordinate movements, and optimize automation concepts early in the engineering process.
Learn how to combine CAD data, KUKA robots, and peripheral equipment in iiQWorks.Sim to create digital twins, perform robot simulations, and virtually plan and validate automation solutions.

Can I create robot programs offline?

Yes. With iiQWorks.Sim, robot programs can be created, tested, and optimized offline. Programming is performed independently of the physical system, eliminating the need to interrupt production. Robot motions, reachability, and cycle times can be simulated and validated in advance before the program is transferred to the robot.

Which PLC systems does iiQWorks.Sim support?

iiQWorks.Sim supports connectivity with PLCs and automation systems. Standard communication protocols such as OPC UA enable data and signal exchange between simulation models and control systems, supporting virtual commissioning and automation validation.
Learn how to connect KUKA robots to CODESYS via OPC UA in iiQWorks.Sim and configure I/O signals for virtual commissioning.

What is robot simulation software used for?

Robot simulation software is used to virtually plan, validate, and optimize robots, robotic cells, and production processes before they are deployed in a real manufacturing environment. Companies use it for tasks such as offline robot programming, collision detection, reachability analysis, and the virtual commissioning of complete production systems.

It also supports the planning and validation of automation solutions, as well as the creation of digital twins for manufacturing and logistics processes.

Typical applications include:

  • Planning new robotic cells
  • Optimizing existing production systems
  • Offline robot programming
  • Virtual commissioning
  • Cycle time and throughput analysis
  • Collision detection and reachability analysis
  • Simulation of material flows and logistics processes
  • Validation of PLC and automation concepts
  • Creation of digital twins for manufacturing systems

How accurate are cycle-time simulations?

The accuracy of cycle-time simulations depends on the quality of the available models and project data. By providing realistic representations of robots, tools, processes, and motion sequences, simulations deliver reliable estimates of cycle times and production performance, even during early project phases.

iiQWorks Video Tutorials

Learn how to plan, simulate, and deploy your robot applications with iiQWorks — step by step

Everything you need to get started with robot simulation