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Program not running correct after manual alignment

Bayaz
I made a simple program in the offline mode with the model on the CMM. After I do the manual alignment (plane-circle-circle) it seems to measure everything with an offset. In DCC mode it measures the plane a few hundred thousandths off and crashes on the side of the first circle as if the circle is too small. I've verified the vectors are correct on the model and on the alignment features (and they are aligned in the correct order). The main hole is over 2" and I changed the hole diameter to .375 in the program and it still wants to crash. I've tried CAD=part, I've moved the manual alignment around, and few other tricks but it just doesn't want to run. The path lines look good and simulates perfect. This is the 3rd time on this machine this has happened. I've never seen this problem before. This machine is really ticking me off! It's a 6month old Hexagon global performance running PCdmis 2015.0 Any help would be greatly appreciated.
  • I see this frequently and while not positive, I'm convinced it has something to do with the transition from offline to machine.

    Anyway, Two options here. Both may or may not work but one definitely should:

    1> Perform your manual alignment then Cancel the program and start it over from the DCC ON command...If that doesn't work...

    2> Go to one of your DCC alignment features...Edit the theoretical location of one or all axis by deleting whats there and typing in the same thing, for example, if the theoretical location of your dcc plane is (0,0,0) delete the zero in the "Z" spot and type in a zero. When you click out of that field PCDMIS should ask if you want to update all commands below that point with the new alignment...Click YES

    3> Run program from DCC on command

    If this works the program will run fine until the next Manual alignment at which point the above procedure will have to be repeated. If it doesn't work then your having an issue that sounds just like my issue but is actually different. I hop this works for ya cause I know how extremely aggravating this is....Good Luck
  • Post some code especially the alignment.....

    Did you use auto features or create the features?
  • Metric vs inch mistake ? Without code...I'm putting money on alignment. Its always the safe bet.
  • I see this frequently - it's the alignment.

    Post the alignment.
  • I used a measured plane and auto circle for -B- and -C-. I'm new to this company and there models have been pretty terrible. I am staring to wonder if it is something specific to this machine.
    LOADPROBE/PE50_2X50
    WORKPLANE/YMINUS
    TIP/T1A90B180, SHANKIJK=0, -1, 0, ANGLE=180
    PLN1 =FEAT/PLANE,CARTESIAN,TRIANGLE
    THEO/<3.1812,0.2344,3.1498>,<0,-1,0>
    ACTL/<3.1812,0.2344,3.1498>,<0,-1,0>
    MEAS/PLANE,4
    HIT/BASIC,NORMAL,<3.3591,0.2344,5.2324>,<0,-1,0>,<3.3591,0.2344,5.2324>,USE THEO=YES
    HIT/BASIC,NORMAL,<3.0694,0.2344,1.1331>,<0,-1,0>,<3.0694,0.2344,1.1331>,USE THEO=YES
    HIT/BASIC,NORMAL,<5.2231,0.2344,3.0655>,<0,-1,0>,<5.2231,0.2344,3.0655>,USE THEO=YES
    HIT/BASIC,NORMAL,<1.0732,0.2344,3.1681>,<0,-1,0>,<1.0732,0.2344,3.1681>,USE THEO=YES
    ENDMEAS/
    CIR1 =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
    THEO/<3.245,0.2344,3.2328>,<0,-1,0>,2.04
    ACTL/<3.245,0.2344,3.2328>,<0,-1,0>,2.04
    TARG/<3.245,0.2344,3.2328>,<0,-1,0>
    START ANG=0,END ANG=360
    ANGLE VEC=<1,-0.0000029,0>
    DIRECTION=CCW
    SHOW FEATURE PARAMETERS=NO
    SHOW CONTACT PARAMETERS=YES
    NUMHITS=4,DEPTH=0.08,PITCH=0
    SAMPLE METHOD=SAMPLE_HITS
    SAMPLE HITS=0,SPACER=0
    AVOIDANCE MOVE=BOTH,DISTANCE=0.2
    FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
    SHOW HITS=NO
    CIR2 =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
    THEO/<2.0439,0.3566,9.3752>,<0,-1,0>,0.5645
    ACTL/<2.0439,0.3566,9.3752>,<0,-1,0>,0.5645
    TARG/<2.0439,0.3566,9.3752>,<0,-1,0>
    START ANG=0,END ANG=360
    ANGLE VEC=<0.9998767,0.015706,0>
    DIRECTION=CCW
    SHOW FEATURE PARAMETERS=NO
    SHOW CONTACT PARAMETERS=YES
    NUMHITS=4,DEPTH=0.08,PITCH=0
    SAMPLE METHOD=SAMPLE_HITS
    SAMPLE HITS=0,SPACER=0
    AVOIDANCE MOVE=BOTH,DISTANCE=0.2
    FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
    SHOW HITS=NO
    LIN1 =FEAT/LINE,CARTESIAN,UNBOUNDED,NO
    THEO/<3.245,0.2344,3.2328>,<-0.1918632,0.0195164,0.9812276>
    ACTL/<3.245,0.2344,3.2328>,<-0.1918632,0.0195164,0.9812276>
    CONSTR/LINE,BF,3D,CIR1,CIR2,,
    OUTLIER_REMOVAL/OFF,3
    FILTER/OFF,WAVELENGTH=0
    A1 =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
    ALIGNMENT/LEVEL,YMINUS,PLN1
    ALIGNMENT/TRANS,YAXIS,PLN1
    ALIGNMENT/ROTATE,ZPLUS,TO,LIN1,ABOUT,YMINUS
    ALIGNMENT/TRANS,XAXIS,LIN1
    ALIGNMENT/TRANS,ZAXIS,CIR1
    ALIGNMENT/END
    -A- =FEAT/PLANE,CARTESIAN,TRIANGLE
    THEO/<-0.0344,0,-0.0282>,<0,-1,0>
    ACTL/<-0.0344,0,-0.0282>,<0,-1,0>
    MEAS/PLANE,4
    HIT/BASIC,NORMAL,<0.296,0,2.3185>,<0,-1,0>,<0.296,0,2.3185>,USE THEO=YES
    HIT/BASIC,NORMAL,<2.2254,0,-0.3419>,<0,-1,0>,<2.2254,0,-0.3419>,USE THEO=YES
    HIT/BASIC,NORMAL,<-0.2525,0,-2.4656>,<0,-1,0>,<-0.2525,0,-2.4656>,USE THEO=YES
    HIT/BASIC,NORMAL,<-2.4066,0,0.3762>,<0,-1,0>,<-2.4066,0,0.3762>,USE THEO=YES
    ENDMEAS/
    A2 =ALIGNMENT/START,RECALL:A1,LIST=YES
    ALIGNMENT/LEVEL,YMINUS,-A-
    ALIGNMENT/TRANS,YAXIS,-A-
    ALIGNMENT/END
    -B- =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
    THEO/<0,0,0>,<0,-1,0>,2.04
    ACTL/<0,0,0>,<0,-1,0>,2.04
    TARG/<0,0,0>,<0,-1,0>
    START ANG=0,END ANG=360
    ANGLE VEC=<0.9814145,0.0000015,-0.1918997>
    DIRECTION=CCW
    SHOW FEATURE PARAMETERS=NO
    SHOW CONTACT PARAMETERS=YES
    NUMHITS=4,DEPTH=0.08,PITCH=0
    SAMPLE METHOD=SAMPLE_HITS
    SAMPLE HITS=0,SPACER=0
    AVOIDANCE MOVE=BOTH,DISTANCE=0.2
    FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
    SHOW HITS=NO
    -C- =FEAT/CONTACT/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
    THEO/<0,0.1222,6.2587>,<0,-1,0>,0.5645
    ACTL/<0,0.1222,6.2587>,<0,-1,0>,0.5645
    TARG/<0,0.1222,6.2587>,<0,-1,0>
    START ANG=0,END ANG=360
    ANGLE VEC=<0.9812935,0.0157057,-0.191876>
    DIRECTION=CCW
    SHOW FEATURE PARAMETERS=NO
    SHOW CONTACT PARAMETERS=YES
    NUMHITS=4,DEPTH=0.08,PITCH=0
    SAMPLE METHOD=SAMPLE_HITS
    SAMPLE HITS=0,SPACER=0
    AVOIDANCE MOVE=BOTH,DISTANCE=0.2
    FIND HOLE=DISABLED,ONERROR=NO,READ POS=NO
    SHOW HITS=NO
    LIN2 =FEAT/LINE,CARTESIAN,UNBOUNDED,NO
    THEO/<0,0,0>,<0.0000001,0.0195163,0.9998095>
    ACTL/<0,0,0>,<0.0000001,0.0195163,0.9998095>
    CONSTR/LINE,BF,3D,-B-,-C-,,
    OUTLIER_REMOVAL/OFF,3
    FILTER/OFF,WAVELENGTH=0
    A3 =ALIGNMENT/START,RECALL:A2,LIST=YES
    ALIGNMENT/ROTATE,ZPLUS,TO,LIN2,ABOUT,YMINUS
    ALIGNMENT/TRANS,XAXIS,-B-
    ALIGNMENT/TRANS,ZAXIS,-B-
    ALIGNMENT/END
  • 1) don't use anything but letters numbers and underscores in feature / dimension / alignment names - so call it DAT_A not -A-

    2) You've alignments which don't constrain all 6 degrees of freedom (i.e. you've a level and an origin on that axis, but no rotation), some will point to this being the problem. It might be, but it's likely there's something else amiss.

    Little trick - even when not using CAD, click CAD=Part after your manual alignment, this will correct your manual alignment Theo values.
  • After you take the first plane, set it as your workplane for the circles.
  • loadprobe/pe50_2x50
 workplane/yminus
 tip/t1a90b180, shankijk=0, -1, 0, angle=180
 pln1 =feat/plane,cartesian,triangle
 theo/<3.1812,0.2344,3.1498>,<0,-1,0>
 actl/<3.1812,0.2344,3.1498>,<0,-1,0>
 meas/plane,4
 hit/basic,normal,<3.3591,0.2344,5.2324>,<0,-1,0>,<3.3591,0.2344,5.2324>,use theo=yes
 hit/basic,normal,<3.0694,0.2344,1.1331>,<0,-1,0>,<3.0694,0.2344,1.1331>,use theo=yes
 hit/basic,normal,<5.2231,0.2344,3.0655>,<0,-1,0>,<5.2231,0.2344,3.0655>,use theo=yes
 hit/basic,normal,<1.0732,0.2344,3.1681>,<0,-1,0>,<1.0732,0.2344,3.1681>,use theo=yes
 endmeas/
 cir1 =feat/contact/circle/default,cartesian,in,least_sqr
 theo/<3.245,0.2344,3.2328>,<0,-1,0>,2.04
 actl/<3.245,0.2344,3.2328>,<0,-1,0>,2.04
 targ/<3.245,0.2344,3.2328>,<0,-1,0>
 start ang=0,end ang=360
 angle vec=<1,-0.0000029,0>
 direction=ccw
 show feature parameters=no
 show contact parameters=yes
 numhits=4,depth=0.08,pitch=0
 sample method=sample_hits
 sample hits=0,spacer=0
 avoidance move=both,distance=0.2
 find hole=disabled,onerror=no,read pos=no
 show hits=no
 cir2 =feat/contact/circle/default,cartesian,in,least_sqr
 theo/<2.0439,0.3566,9.3752>,<0,-1,0>,0.5645
 actl/<2.0439,0.3566,9.3752>,<0,-1,0>,0.5645
 targ/<2.0439,0.3566,9.3752>,<0,-1,0>
 start ang=0,end ang=360
 angle vec=<0.9998767,0.015706,0>
 direction=ccw
 show feature parameters=no
 show contact parameters=yes
 numhits=4,depth=0.08,pitch=0
 sample method=sample_hits
 sample hits=0,spacer=0
 avoidance move=both,distance=0.2
 find hole=disabled,onerror=no,read pos=no
 show hits=no
 lin1 =feat/line,cartesian,unbounded,no
 theo/<3.245,0.2344,3.2328>,<-0.1918632,0.0195164,0.9812276>
 actl/<3.245,0.2344,3.2328>,<-0.1918632,0.0195164,0.9812276>
 constr/line,bf,3d,cir1,cir2,,
 outlier_removal/off,3
 filter/off,wavelength=0
 a1 =alignment/start,recall:startup,list=yes
 alignment/level,yminus,pln1
 alignment/trans,yaxis,pln1
 alignment/rotate,zplus,to,lin1,about,yminus
 alignment/trans,xaxis,lin1
 alignment/trans,zaxis,cir1
 alignment/end
 -a- =feat/plane,cartesian,triangle
 theo/<-0.0344,0,-0.0282>,<0,-1,0>
 actl/<-0.0344,0,-0.0282>,<0,-1,0>
 meas/plane,4
 hit/basic,normal,<0.296,0,2.3185>,<0,-1,0>,<0.296,0,2.3185>,use theo=yes
 hit/basic,normal,<2.2254,0,-0.3419>,<0,-1,0>,<2.2254,0,-0.3419>,use theo=yes
 hit/basic,normal,<-0.2525,0,-2.4656>,<0,-1,0>,<-0.2525,0,-2.4656>,use theo=yes
 hit/basic,normal,<-2.4066,0,0.3762>,<0,-1,0>,<-2.4066,0,0.3762>,use theo=yes
 endmeas/
 a2 =alignment/start,recall:a1,list=yes
 alignment/level,yminus,-a-
 alignment/trans,yaxis,-a-
 alignment/end
 -b- =feat/contact/circle/default,cartesian,in,least_sqr
 theo/<0,0,0>,<0,-1,0>,2.04
 actl/<0,0,0>,<0,-1,0>,2.04
 targ/<0,0,0>,<0,-1,0>
 start ang=0,end ang=360
 angle vec=<0.9814145,0.0000015,-0.1918997>
 direction=ccw
 show feature parameters=no
 show contact parameters=yes
 numhits=4,depth=0.08,pitch=0
 sample method=sample_hits
 sample hits=0,spacer=0
 avoidance move=both,distance=0.2
 find hole=disabled,onerror=no,read pos=no
 show hits=no
 -c- =feat/contact/circle/default,cartesian,in,least_sqr
 theo/<0,0.1222,6.2587>,<0,-1,0>,0.5645
 actl/<0,0.1222,6.2587>,<0,-1,0>,0.5645
 targ/<0,0.1222,6.2587>,<0,-1,0>
 start ang=0,end ang=360
 angle vec=<0.9812935,0.0157057,-0.191876>
 direction=ccw
 show feature parameters=no
 show contact parameters=yes
 numhits=4,depth=0.08,pitch=0
 sample method=sample_hits
 sample hits=0,spacer=0
 avoidance move=both,distance=0.2
 find hole=disabled,onerror=no,read pos=no
 show hits=no
 lin2 =feat/line,cartesian,unbounded,no
 theo/<0,0,0>,<0.0000001,0.0195163,0.9998095>
 actl/<0,0,0>,<0.0000001,0.0195163,0.9998095>
 constr/line,bf,3d,-b-,-c-,,
 outlier_removal/off,3
 filter/off,wavelength=0
 a3 =alignment/start,recall:a2,list=yes
 alignment/rotate,zplus,to,lin2,about,yminus
 alignment/trans,xaxis,-b-
 alignment/trans,zaxis,-b-
 alignment/end



    Is this in the middle of the program or at the start of the program?
  • I just posted the manual and DCC alignments. I'm afraid this will probably remain a mystery as this is my last night with this company. I've probably made a thousand programs offline and online and never had that happen until I started at this shop. I finally had enough haggling with engineering to flow down information and provide non-defective models, ugh.

    Thank you guys so much for the pointers. I've lurked around this forum for a long time and value your expertise.
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