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Vision Crashes When Measuring Circles

InspectorJester
Running PC-DMIS 2013 MR1 SP5 on Windows 7 PC connected to an Optiv Performance z443
------------------------------------------------------------------------
Hello!
I have several part programs that run though to completion using touch probes
I received a part that requires vision due to the crossholes (there are a lot) being generally too small

So I created the part program and was faced with many issues...
(Such as all of the numbers randomly changing by thousandths, leaving me to clean up everything with 0+0's!)

However, it is done, and I'm trying to check it, but it crashes at the first measurement.

Strangely enough, it worked before!

I have not been able to run this program all of the way through, it only crashes when it measures a crosshole.

The way the program is set up is it performs an alignment using the touch probe, then switches to the camera
The camera looks for a crosshole, and if it does not find it, it rotates 180° and tries again (where it will find it, or we made the part wrong!) Otherwise it continues as normal.

However pretty much since I added the "OnError" stuff it starts crashing at the hole.

I was able to verify that it works (the OnError) previously, and, upon this discovery, moved on to programming the rest of the part.
I needed to get the crosshole perfect or I couldn't measure the part, you see.

So it worked for a bit, but not anymore, and it keeps crashing. Strange!

I tried to measure a different hole in the same program, and had the same issue.

What's going on?
  • Can you provide a sketch of the part you are measuring? In addition, please provide the snippet of code with all parameters expanded for the hole you are trying to measure. It sounds like maybe there is an edge scanning the incorrect way, going light to dark instead of dark to light.
  • I can't provide a sketch of the part, but it is a simple and common feature, so a description should suffice.
    I am measuring the distance from the face of a cylinder to a hole. Alignment is fine, getting to the hole is fine, I can see the hole, I can see that PC-DMIS tries to check it.
    It looks like it crashes as soon as it tries to draw the green points around it.

    I keep attempting to upload an image of the construction of the hole measurement, but it crashes when I open it!!

    I have tried to adjust the number of points (I have point density set to HIGH, maybe changing to LOW or something would help?) but as soon as I try it crashes and closes PC-DMIS

    So here's the code for it, HTH
  • in reply to InspectorJester
    I feel I should mention that I have a program that does more or less the same thing (take point alignment, switch to camera, measure hole) that does not crash, however it also does not have 'on error'.

    I have plenty of programs that use vision and work no problem. I have tried removing the on error command, to no avail.
    I have tried checking different holes, which did not work
    I have tried creating a new circle entirely, which failed miserably.

    I'm not entirely sure what to do, but I'm fiddling with it now. Hopefully someone can point me in the right direction!
    Otherwise I'll post more of my findings as they are, well, found
  • It would appear as though I have multiple problems with this program. I will do my best to explain, hopefully that will help understand.

    I have a cylindrical part.
    The load instructions state to align a feature upright in a rotary table, and you'll be able to run the program. This part is easy.
    However, with other parts I've done, I could find a feature to align upright, and it would work regardless of it was at 0° or 180°, because the features were the same on both sides.

    This part is different.
    I have a hole at one location at 0°, but at 180° there is no hole. So I'm trying to use "OnError" to determine if the hole is there. If it's not, rotate 180° and try again. If it is, continue the program.

    I was able to get this section to work. I set the OnError command to Edge_Not_Detected, GoTo (Label that contains the other circle), which just rotates 180° and measures the same circle.

    A variable is created, determining if I am using the circle at 0° or 180° in relation to the rotab (so I know if I need to rotate and re-align or not)

    The rest of the program continues when the hole is actually measured.

    This worked fine and well, so I moved on to the rest of the program (there are only 48 crossholes of varying diameters and locations, not a waste of time at all!)

    When I finished the program (without creating dimensions, I just wanted to see if it would even run before I messed around with them!) that section stopped working.

    Not only that, every Vision circle I tried to measure in that program crashes PC-DMIS!

    So I more or less created a [theoretically] good program, but it doesn't want to run through for some reason.
    ----------------------------------------------------------------------------------------------------------------------------------------------------
    Randomly throughout the program, Everything would change and be funky.

    Vectors of {0,0,1} were transforming to random gibberish (sometimes they would even be in the same plane I left them!)
    More often than not 0,0,1 would become {-.000000015648, .0946521, -.99999784135484} or some such nonsense (notice the sign change)
    XYZ values would jumble around a few thousandths intermittently
    Fun!

    Well, I read that pretty much to prevent that, switch all the {0,0,1} with {0+0,0+0,1}, so I went through the painstaking process of adjusting all of them.
    I didn't really understand, because the ones I set to 0+0 would stay 0, but ones (say, X 2.765) would change. So I changed stuff to more or less 2.765+0.

    But it doesn't work. I can measure holes with Vision in other programs, I even added some line measurements to this one right after the probe change but before the holes. They work fine! The holes don't!
  • I am unfamiliar with Rotary Tables, maybe could be of better assistance to you. My question is why do you use both top and ring light together? I haven't done it this way, I use one or the other. Maybe your part is a little different than what I run.

    If vectors are changing on you, I am curious as to how your alignment is set up. In addition, how do you calibrate your touch probes to vision?
  • Im pretty sure the ring light is redundant, I really only need the top light. I just have it on because I haven't bothered to turn it off!

    I calibrate the standard way: Using the hexagon calibration plate.

    Measure the ring with vision, has moved, measure with probe, has not, measure sphere with probe, has moved, measure every other probe, has not

    The alignment takes 4 cylinders, 7 hits per ring, two rings, along the OD.
    1 point is taken on the face, and a plane of 6 points is taken inside a notch (to align upright)

    I level Y+ to the cylinder, rotate ZPlus to the plane about YPlus, Rotate YPlus to the cylinder about XPlus, Set X&Z axes to cylinder, set Y axis to face point.

    Then I measure a line on the face using vision, and I measure a line on an undercut. After that is the hole that crashes.

    If the hole is there, it crashes right away.
    If it's not, the program rotates 180° and measures the hole, and crashes right away


  • The alignment takes 4 cylinders, 7 hits per ring, two rings, along the OD.
    1 point is taken on the face, and a plane of 6 points is taken inside a notch (to align upright)

    I level Y+ to the cylinder, rotate ZPlus to the plane about YPlus, Rotate YPlus to the cylinder about XPlus, Set X&Z axes to cylinder, set Y axis to face point.

    Then I measure a line on the face using vision, and I measure a line on an undercut. After that is the hole that crashes.

    If the hole is there, it crashes right away.
    If it's not, the program rotates 180° and measures the hole, and crashes right away

    Can you post the code ?
    Why do you rotate twice ?
    Did you change any parameter on the PC (driver, video card...) ?
    Does the rtary gives correct values when it turns ? (for example, if the rotary turns around Y+ (part coordinates), Z and X should change of sign on a 180° rotation.

    You could also check all the dlls...
  • in reply to bfire85
    Thanks for your trust, even I can disappoint !
    I don't know about Optiv...
  • The second rotation is redundant.
    I was told (as a "best practice") to have a level, two rotates, and 3 origins in an alignment. I only need to level to Y to achieve rotate Y about X.
    And yes: 
    
FINE_ALIGN_0=ALIGNMENT/START,RECALL:STARTUP,LIST=YES
            ALIGNMENT/LEVEL,YPLUS,FA_CYLOD
            ALIGNMENT/ROTATE,ZPLUS,TO,FA_PLNROT,ABOUT,YPLUS
            ALIGNMENT/ROTATE,YPLUS,TO,FA_CYLOD,ABOUT,XPLUS
            ALIGNMENT/TRANS,XAXIS,FA_CYLOD
            ALIGNMENT/TRANS,ZAXIS,FA_CYLOD                *Full DCC alignment
            ALIGNMENT/TRANS,YAXIS,FA_PNTFACE
            ALIGNMENT/END
            CLEARP/ZPLUS,0.5,ZPLUS,0,OFF
            MOVE/CLEARPLANE
            MOVE/ROTAB,0,SHORTEST,FA_PLNROT                *Rotate to the plane
            LOADPROBE/NO PROBE ATTACHED                    *Take off touch probe
            LOADPROBE/ZOOM                        *Switch to camera probe
            TIP/TIP1, SHANKIJK=0, 0, 1, ANGLE=0
VIS_FACE   =FEAT/VISION/LINE/DEFAULT,CARTESIAN,BOUNDED
            THEO/<-0.05,0,0.36>,<0.05,0,0.36>,<1,0,0>,<0,1,0>,<0,0,1>,0.1
            ACTL/<-0.05,0,0.365>,<0.05,0,0.365>,<1,0,0>,<0,1,0>,<0,0,1>,0.1
            TARG/<-0.05,0,0.36>,<0.05,0,0.36>,<1,0,0>,<0,1,0>,<0,0,1>
            SHOW FEATURE PARAMETERS=YES
              SURFACE=THEO_THICKNESS,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE                    *Take a line on the face
              CIRCULAR MOVES=NO
              CLEARPLANE=NO
              PREPOSITION=NO
              GRAPHICAL ANALYSIS=NO
              DIAGNOSTICS=NO
              FEATURE LOCATOR=NO,NO,""
            SHOW_VISION_PARAMETERS=YES
              TYPE=AUTOMATIC HIT TARGET
              COVERAGE=100%
              COVERAGE ACTIVE TARGETS=4
              MAGNIFICATION=1.5001
              HIT TARGET COLOR=RED,NOMINAL COLOR=GREEN
              HIT TARGET=EA1,0,1,HIGH,0.0067
              FILTER=NO,YES,0,2.25
              EDGE=SPECIFIED EDGE,15,[ ]->[|],-->,1,1,1,1,NO,Backlight=<OFF,0,OFF>,Toplight=<OFF,83.1,ON>,Ringlight=<OFF,55.9,ON>
              FOCUS=NO
A10        =ALIGNMENT/START,RECALL:STARTUP,LIST=YES
            ALIGNMENT/LEVEL,YPLUS,FA_CYLOD
            ALIGNMENT/ROTATE,ZPLUS,TO,FA_PLNROT,ABOUT,YPLUS
            ALIGNMENT/ROTATE,YPLUS,TO,FA_CYLOD,ABOUT,XPLUS
            ALIGNMENT/TRANS,XAXIS,FA_CYLOD                *"More accurate" Full DCC Alignment
            ALIGNMENT/TRANS,ZAXIS,FA_CYLOD
            ALIGNMENT/TRANS,YAXIS,VIS_FACE
            ALIGNMENT/END
UC_1       =FEAT/VISION/LINE/DEFAULT,CARTESIAN,BOUNDED
            THEO/<-0.05,1.393,0.38>,<0.05,1.393,0.38>,<1,0,0>,<0,1,0>,<0,0,1>,0.1
            ACTL/<-0.05,1.393,0.38>,<0.05,1.393,0.38>,<1,0,0>,<0,1,0>,<0,0,1>,0.1
            TARG/<-0.05,1.393,0.38>,<0.05,1.393,0.38>,<1,0,0>,<0,1,0>,<0,0,1>
            SHOW FEATURE PARAMETERS=YES
              SURFACE=THEO_THICKNESS,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              CIRCULAR MOVES=NO
              CLEARPLANE=NO
              PREPOSITION=NO
              GRAPHICAL ANALYSIS=NO
              DIAGNOSTICS=NO                        *Measure an undercut with a line
              FEATURE LOCATOR=NO,NO,""
            SHOW_VISION_PARAMETERS=YES
              TYPE=AUTOMATIC HIT TARGET
              COVERAGE=100%
              COVERAGE ACTIVE TARGETS=4
              MAGNIFICATION=1.5001
              HIT TARGET COLOR=RED,NOMINAL COLOR=GREEN
              HIT TARGET=EA1,0,1,HIGH,0.01
              FILTER=NO,YES,0,2.25
              EDGE=SPECIFIED EDGE,5,[|]->[ ],-->,1,1,1,1,NO,Backlight=<OFF,0,OFF>,Toplight=<OFF,34.7,ON>,Ringlight=<OFF,55.9,ON>
              FOCUS=NO                        
            ONERROR/EDGE_NOT_DETECTED,GOTO LBL_HOLEALIGN        *Begin Hole measurements
CIR_0      =FEAT/VISION/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR    
            THEO/<0+0,1.595,0.365>,<0+0,0+0,1>,0.033,0,0
            ACTL/<0.0069,1.5958,0.3648>,<0.0751523,0.0002583,0.997172>,0.0366,0,0
            TARG/<0+0,1.595,0.365>,<0+0,0+0,1>
            ANGLE VEC=<-1,0+0,0+0>
            SHOW FEATURE PARAMETERS=YES
              SURFACE=THEO_THICKNESS,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              CIRCULAR MOVES=NO
              CLEARPLANE=NO
              PREPOSITION=NO
              GRAPHICAL ANALYSIS=NO
              DIAGNOSTICS=NO                        *If the hole is there, GoTo LBL_HOLE
              FEATURE LOCATOR=NO,NO,""                    *If the hole is not, GoTo LBL_HoleAlign
            SHOW_VISION_PARAMETERS=YES
              TYPE=AUTOMATIC HIT TARGET
              COVERAGE=100%
              COVERAGE ACTIVE TARGETS=4
              MAGNIFICATION=1.5001
              HIT TARGET COLOR=RED,NOMINAL COLOR=GREEN
              HIT TARGET=EA1,0,1,NORMAL,0.0163
              FILTER=NO,NO
              EDGE=MATCHING EDGE,15,[|]->[ ],<--,1,1,1,NO,Backlight=<OFF,0,OFF>,Toplight=<OFF,55,ON>,Ringlight=<OFF,55.9,ON>
              FOCUS=NO
            ONERROR/EDGE_NOT_DETECTED,OFF
            ASSIGN/VHOLE={CIR_0}
            ASSIGN/VROT=0
            GOTO/LBL_HOLE
LBL_HOLEALIGN=LABEL/                            *Do this if the hole is not there
            ASSIGN/VROT=180
            MOVE/ROTAB,180,SHORTEST,FA_PLNROT
FINE_ALIGN_180=ALIGNMENT/START,RECALL:STARTUP,LIST=YES
            ALIGNMENT/LEVEL,YPLUS,FA_CYLOD
            ALIGNMENT/ROTATE,ZPLUS,TO,FA_PLNROT,ABOUT,YPLUS
            ALIGNMENT/ROTATE_OFFSET,180,ABOUT,YPLUS
            ALIGNMENT/ROTATE,YPLUS,TO,FA_CYLOD,ABOUT,XPLUS
            ALIGNMENT/TRANS,XAXIS,FA_CYLOD
            ALIGNMENT/TRANS,ZAXIS,FA_CYLOD                *Adjust alignment to be rotated 180°
            ALIGNMENT/TRANS,YAXIS,FA_PNTFACE
            ALIGNMENT/END
CIR_180    =FEAT/VISION/CIRCLE/DEFAULT,CARTESIAN,IN,LEAST_SQR
            THEO/<0+0,1.595,0.365>,<0+0,0+0,1>,0.033,0,0
            ACTL/<-0.0019,1.5959,0.365>,<0.0000573,0.0010758,0.9999994>,0.0368,0,0
            TARG/<0+0,1.595,0.365>,<0+0,0+0,1>
            ANGLE VEC=<-1,0+0,0+0>
            SHOW FEATURE PARAMETERS=YES
              SURFACE=THEO_THICKNESS,0
              MEASURE MODE=NOMINALS
              RMEAS=NONE,NONE,NONE
              CIRCULAR MOVES=NO
              CLEARPLANE=NO
              PREPOSITION=NO
              GRAPHICAL ANALYSIS=NO                    *Measure this hole
              DIAGNOSTICS=NO
              FEATURE LOCATOR=NO,NO,""
            SHOW_VISION_PARAMETERS=YES
              TYPE=AUTOMATIC HIT TARGET
              COVERAGE=100%
              COVERAGE ACTIVE TARGETS=4
              MAGNIFICATION=1.5001
              HIT TARGET COLOR=RED,NOMINAL COLOR=GREEN
              HIT TARGET=EA1,0,1,HIGH,0.0163
              FILTER=NO,YES,0,2.25
              EDGE=MATCHING EDGE,15,[|]->[ ],<--,1,1,1,NO,Backlight=<OFF,0,OFF>,Toplight=<OFF,55,ON>,Ringlight=<OFF,55.9,ON>
              FOCUS=NO
            ASSIGN/VHOLE={CIR_180}                    *Continue on as normal
LBL_HOLE   =LABEL/
HOLE_1.595 =GENERIC/CIRCLE,DEPENDENT,CARTESIAN,OUT,$
            NOM/XYZ,<VHOLE.X,VHOLE.Y,VHOLE.Z>,$
            MEAS/XYZ,<VHOLE.X,VHOLE.Y,VHOLE.Z>,$
            NOM/IJK,<VHOLE.I,VHOLE.J,VHOLE.K>,$
            MEAS/IJK,<VHOLE.I,VHOLE.J,VHOLE.K>,$
            DIAMETER/VHOLE.D,VHOLE.D
FINE_ALIGN_START=ALIGNMENT/START,RECALL:STARTUP,LIST=YES
            ALIGNMENT/LEVEL,YPLUS,FA_CYLOD
            ALIGNMENT/ROTATE,ZPLUS,TO,FA_PLNROT,ABOUT,YPLUS
            ALIGNMENT/ROTATE_OFFSET,VROT,ABOUT,YPLUS
            ALIGNMENT/ROTATE,YPLUS,TO,FA_CYLOD,ABOUT,XPLUS
            ALIGNMENT/TRANS,XAXIS,FA_CYLOD
            ALIGNMENT/TRANS,ZAXIS,HOLE_1.595
            ALIGNMENT/TRANS,YAXIS,FA_PNTFACE
            ALIGNMENT/END

$$ NO,
            VROT is the rotation of the 1.595 Hole

            CLEARP/ZPLUS,0.5,ZPLUS,0,OFF
            MOVE/ROTAB,VROT,SHORTEST,FA_PLNROT
  • in reply to InspectorJester
    Numbers have been changed to protect the identity of the deceased
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