Alignment Help

You need two alignments. A manual alignment and DCC alignment. The simplest way to do that is create the manual alignment and just use the same exact alignment for DCC. Then you can program your features.

Let's see your code

Gotta tell the machine where part is & how it is oriented. Using some alignments from somewhere is crap waiting to happen. Manual alignment: 6 hits on cylinder for level & origin Z&X. Face plane for Y origin. Position the part so one spline is as vertical as possible. 1st point on left top spline 2nd on the next right one to construct mid point. Rotate cylinder to mid point to Z axis. Repeat in DCC.

below is the code for the alignment and first two features


STARTUP =ALIGNMENT/START,RECALL:USE_PART_SETUP,LIST=YES
ALIGNMENT/END
MODE/MANUAL
FORMAT/TEXT,OPTIONS, ,HEADINGS,SYMBOLS, ;NOM,TOL,MEAS,DEV,OUTTOL, ,
LOADPROBE/HP-TM-SF
TIP/T1A0B0, SHANKIJK=0, -1, 0, ANGLE=0
CYL1 =FEAT/CYLINDER,CARTESIAN,OUT,LEAST_SQR
THEO/<0,5.21652,0>,<0,1,0>,1.5005,1.39781
ACTL/<5.3017,5.49178,-14.46039>,<-0.022101,0.9960705,-0.0857624>,1.50064,1.31295
MEAS/CYLINDER,6
HIT/BASIC,NORMAL,<0.62879,4.57811,0.40927>,<0.8381035,0,0.5455112>,<5.98615,4.96956,-14.08055>,USE THEO=YES
MOVE/CIRCULAR
HIT/BASIC,NORMAL,<-0.04827,4.51761,0.7487>,<-0.0643375,0,0.9979282>,<5.24166,4.96909,-13.66588>,USE THEO=YES
MOVE/CIRCULAR
HIT/BASIC,NORMAL,<-0.67314,4.53435,0.3313>,<-0.8972201,0,0.4415836>,<4.66014,4.85465,-14.04037>,USE THEO=YES
MOVE/CIRCULAR
HIT/BASIC,NORMAL,<-0.69914,5.83089,0.27217>,<-0.9318786,0,0.3627704>,<4.66996,5.93832,-14.07837>,USE THEO=YES
MOVE/CIRCULAR
HIT/BASIC,NORMAL,<-0.05682,5.83077,0.7481>,<-0.0757293,0,0.9971284>,<5.25137,6.02607,-13.75435>,USE THEO=YES
MOVE/CIRCULAR
HIT/BASIC,NORMAL,<0.662,5.91542,0.35303>,<0.8823751,0,0.4705466>,<5.9543,6.1898,-14.17614>,USE THEO=YES
ENDMEAS/
PLN1 =FEAT/PLANE,CARTESIAN,TRIANGLE
THEO/<-0.05809,0,0.51964>,<0,-1,0>
ACTL/<5.3769,0.27194,-13.46118>,<0.0223856,-0.9960619,0.0857876>
MEAS/PLANE,3
HIT/BASIC,NORMAL,<0.51434,0,0.48791>,<0,-1,0>,<5.99959,0.28214,-13.50528>,USE THEO=YES
HIT/BASIC,NORMAL,<-0.05682,0,0.68813>,<0,-1,0>,<5.40966,0.28901,-13.27156>,USE THEO=YES
HIT/BASIC,NORMAL,<-0.63179,0,0.38288>,<0,-1,0>,<4.72146,0.24468,-13.6067>,USE THEO=YES
ENDMEAS/
MODE/DCC
A1 =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
ALIGNMENT/TRANS,XAXIS,CYL1
ALIGNMENT/TRANS,ZAXIS,CYL1
ALIGNMENT/LEVEL,YMINUS,PLN1
ALIGNMENT/TRANS,YAXIS,PLN1
ALIGNMENT/END
END PLANE =FEAT/PLANE,CARTESIAN,TRIANGLE
THEO/<-0.01201,-1.242,0.0678>,<0,-1,0>
ACTL/<-5.33864,-1.2375,14.41287>,<-0.0019209,-0.0857876,0.9963116>
MEAS/PLANE,3
MOVE/POINT,NORMAL,<0.39437,10.67155,14.3923>
HIT/BASIC,NORMAL,<-0.25554,-1.242,-0.01144>,<0,-1,0>,<-5.58388,-1.31099,14.40607>,USE THEO=YES
HIT/BASIC,NORMAL,<-0.02078,-1.242,0.2397>,<0,-1,0>,<-5.34357,-1.06609,14.42762>,USE THEO=YES
HIT/BASIC,NORMAL,<0.24028,-1.242,-0.02485>,<0,-1,0>,<-5.08848,-1.33544,14.40492>,USE THEO=YES
ENDMEAS/
27 SPLINE FACE=FEAT/PLANE,CARTESIAN,TRIANGLE
THEO/<-0.03469,0,0.42357>,<0,-1,0>
ACTL/<-5.35099,-0.77608,13.20598>,<-0.0019209,-0.0857876,0.9963116>
MEAS/PLANE,3
MOVE/POINT,NORMAL,<-0.10363,11.597,14.16869>
HIT/BASIC,NORMAL,<-0.72616,0,0.24911>,<0,-1,0>,<-6.04618,-0.93437,13.19101>,USE THEO=YES
HIT/BASIC,NORMAL,<-0.06624,0,0.74098>,<0,-1,0>,<-5.37546,-0.45921,13.23322>,USE THEO=YES
HIT/BASIC,NORMAL,<0.68833,0,0.28063>,<0,-1,0>,<-4.63134,-0.93464,13.19372>,USE THEO=YES
ENDMEAS/
MODE/MANUAL

I wouldn't do a manual cylinder. You are leveling to a plane, so just do a circle. The cylinder can be done in DCC.

Also, do not use spaces or special characters in your features names. Use letters, numbers, and underscores.

After "27 Spline Face", why is manual mode reenabled? I'd be curious as to how your additional alignments are.

The alignment sequence is out should be Level, Rotate, Translate in that order, that should fix the problem

Program in "manual mode" (CTL+ Ff4 key), virtually, by clicking your initial align features on the cad.
create an alignment, and align to those virtually created features. level, rotate, translate as bfire85 mentioned.
then run that routine. and physically take the manual hits
from that point forward your CAD will match the physical location of the part on the machine.

If you probe the part manually, you might be able to get away with doing a CAD=Part align (save a backup copy of your routine first).
--I've avoided that button like the plague as it never worked right for me. Maybe it works better now.

Thank you all for the help. I will do level rotate translate in that order for alignments. I also need to add a dcc alignment.

I reenabled manual to take the hits on the 27 spline major and minor. Since the splines aren't timed with each other they will be in different orientations each part.