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Travel Limits

SAR4U
Good morning all!

Here is a description of what I am working with.
Its a 2012 OPTIV Classic vision cmm with tp20 touch probes with a 3 station tool rack and PC-DMIS 2011 MR1.

Here is the issue-
I just had Hexagon come out and preform the yearly calibration on the machine. And I am now just getting back on the machine after a few weeks. I have made programs on this machine and have preformed calibrations of the camera and probes many times.
Since the calibration I cant get the probes to calibrate continuously. I can calibrate one probe tip at a time and it will calibrate Man+DCC. Until I get to a star probe with five tips, or try to calibrate all 3 probe in the probe rack in sequence (DCC+DCC) it picks up the probe and stops.

I get an error in the execution mode operations window.

it reads "Move commanded outside travel limits"
Move Absolute to X=-1.7249 Y=0 Z=3.2249

If I try to move the probe to that location. The probe would be way down below the glass. Also its of from the quall sphere in the X&Y

Is there a setting, or a file that the Service Tech needed to switch, or replace, for calibration that didn't get put back? Its like there is a clearance plane or boundary setting on.
It calibrates when I take a single hit on the quall sphere. But anything other it stops after picking up the probe.


Also none of my programs run.

I have reached out to the Service Tech a few times by phone and email and no replay.

So any ideas, help, or threads that could point me into a direction to resolve this would be greatly appreciated

Thank you in advance!

  • You should calibrate one tip A0B0 saying "Yes, the sphere moved"
  • I have done that. In fact that is the only way I can calibrate any tip. If I go into autocalibrate or try to calibrate the star probe it errors out.

    Where dose it save the location of the quall sphere when you say yes and you pick the sphere A0B0? Its like its not saving the location for the next probe to calibrate.
  • tool.dat in Vista/7: C:\ProgramData\WAI\PC-DMIS\2011 MR1 or XP: C:\Documents and Settings\All Users\Application Data\WAI\PC-DMIS\2011 MR1

    You should also look at the offsets of each probe, or just trying to calibrate them by selecting "reset to theo".
  • What is your calibration procedure? I have an optiv performance 443; if youre seeing this issue, something is wrong with your calibration.
  • I have got the same crap! I've got a 443 Dual Z performance and it barks about the same outside travel limits. The Cal Tool 'plate' is an official Hexagon device!
    You'd think they would have engineered it correctly. It holds the Cal sphere, Offset ring and Optical calibration glass plate.
    The only way I got around the problem is by skipping Tip #3 (pointing Y+) on the 5 tip star. The table has 1" of room (can manually move it there) between the sphere and tip, but the machine balks in DCC
    Absolutely crap indeed! .
  • Hello everyone! I had to step away for some other pressing issues/fires.

    I guess I have a stupid question how do I "reset the theo"?

    I am following the calibration procedure that's in the manual that came with the machine. I am calibrating the camera first and then the probes. Camera as primary, and probes as secondary. Which seems backwards to me. but ok.

    I agree that there is something wrong with the calibration. What is odd is that this worked fine before the tech came and did the certification of the machine. Now it alarms out.

    Again thank you for all the help and advise.

    Sealevel:

    +1
    You have made it further then I have.

  • Ok I have a new clue/twist to this problem.

    So moving the stage around and the head up and down. The XYZ readout corresponds to the axis that is actually moving. When I go into calibration of a probe the X&Y swaps for which axis is actually moving.
    I think this is where the over travel limits error is coming from. "Sealevel, if your having the same problem, check to see if this is happening too"

    Dose anyone know where these axis settings would be? And maybe why the tech would swap the axis for calibration?

    Thank you!
  • SAR4U, I would suggest to you remedies but they might only be ok for my Optiv 443. I would feel bad if I sent you the hockey stick that I 'persuaded' the FDC and jogbox with.
    Your machine might need different medicine.
    I would call Hexagon for the Tech to come back again. Something seems a bit screwy.

    by the way:
    WHEN YOU CALIBRATE THE OFFSET CALIBRATION.... BEFORE YOU DO, MAKE SURE YOU DO NOT HAVE "RESET THE THEO" IN ANY TACTILE PROBES BEFORE YOU RUN IT.

    MAKE SURE YOU DO NOT HAVE "RESET THE THEO" IN ANY TACTILE PROBES BEFORE YOU RUN IT.
    MAKE SURE YOU DO NOT HAVE "RESET THE THEO" IN ANY TACTILE PROBES BEFORE YOU RUN IT.
    MAKE SURE YOU DO NOT HAVE "RESET THE THEO" IN ANY TACTILE PROBES BEFORE YOU RUN IT.

    this check box will JASPER everything!! Rolling eyes
  • sealevel, and all! Well Hexagon Calibration Tech came back out and took an all day look at the machine. He was able to experience the problem all day. And left with no resolve and shaking his head. Then I had an applications engineer stop by. He had me preform 4-5 different quick checks. Just to show him the issue. The issue still showed its ugly head. The tech said huh. Just try running your program again.

    Now the program runs fine. We both look at each other in disbelief. And nothing was changed. What the heck.
    So I have no answers to what was wrong, and what was fixed.

    After the program ran all the way through. I did have to change a go home, "out of the way move/point."
    I am now thinking something was change on the previous calibration. Then when this last calibration was preformed "by a different tech" the machine was put back to an original setting? Maybe?

    Sorry for not having any solutions that I can pass on.

    Again thank you everyone for your help, time, and input.
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