Optical Calibration Standard targets seem out of sequence - vision probe calibration

Other likely irrelevant details:
I bought the machine used, and "broken". I suspected it took a surge, and being a software engineer with a strong background in electronics, I gambled that I could repair the machine. So far the gable paid off. It had an x axis issue where it wouldn't home. It ended up needing a new glass scale encoder and a new servo amp (along with fixing the software settings that someone messed with trying to "fix" it. All axes home, and I can take measurements....just with the zoom fixed. Why suspect a surge? They said they had already replaced the power supply, and motherboard. By power supply they meant both the computer's supply and the CMM's power supply. seems like a surge was quite likely.
The Computer this is running on is a new core i5 9th gen on windows 10 x64. (Yup, you can still get motherboards with 2 pci slots!) I'm using the IDS Falcon video capture since the matrox card ridiculously doesn't support x64.
I'm about to try switching back to the original computer/capture card just to factor that out, but I strongly suspect software configuration.

From ftp :
IDS_45100.exe What is it? PC-DMIS Framegrabber standard Device Driver Installation Utility for PC-DMIS 2010 and later.
for IDS Falcon and Eagle.
Install the software before installing the framegrabber board.
NOTE: The IDS framegrabbers must not be used on a PC with a TV card driver (such as WinTV from Hauppauge) or other drivers for multimedia cards using a Bt848 or Bt878 chip.
These drivers may overwrite the IDS EEPROM (error code 14) and make the board unusable.
After running IDS_34`00.exe additional information can be found in Program Files\IDs\Falcon\Help\Falcon_Eagle_ENU.pdf.
Support in PCDMIS requires a WAI_FrameGrabber_IDS dll (the initial version will be posted here on the FTP site) and that the HKEY_LOHKEY_LOCAL_MACHINE\Software\WAI\PC-DMIS\MSI\FrameGrabber_Type registry value be set to 201 for Falcon and 202 for Eagle.
How to use? Standard Install. Run IDS_45100.exe

ftp://ftp.wilcoxassoc.com/Hardware/V...meGrabber/IDS/

Hope this helps...

Well, as usual, I don't seem to have been clear. I'm running PC-DMIS 2010r2, so I'm good there, and without the registry setting and the DLL, I wouldn't have been able to get the screenshots I posted. (trust me, I know for a fact what happens when you get it wrong )

What I fear is that perhaps the calibration standard has been updated somehow since PC-DMIS 2010, and I either need an old standard, or new software.

Could it be an issue with PCD 2010 and Windows 10?

It has the same issue on XP.

I think though that with some research, I'm onto the problem, but can't seem to get to the solution yet. The computer that came with this has only fixed probe/calibration files. So I have .75 or 1x. The machine however, is actually a .7 to 4.5 motorized zoom. So .75 and 1.0 calibrated probe files means everything "looks" wrong. Honestly, I;ve been testing with the file marked 1.0, so its probably really bad. I may try the .75 and see if it makes a difference.

So, any ideas on this? Does anyone in here have a visio 300 dcc with motorized zoom who wants to send me the as-shipped prb/ocf/whatever else I need files that allows zooming? Do you think Hexagon who now owns tesa might have it? I'm so close to having this thing working exactly as I want/need it to after 4 weeks of non-stop working on it. Granted, I probably spent waaaaaay too much time getting PC-DMIS 2010 to work on Windows 10 x64! If anyone wants the "magic formula" to make this work I'm more than willing to post. It was pretty easy, though slightly hackish

So I went through all the CD's I have that came with the machine. Sees the only place I have Tesa items defined were on the PC-DMIS DVDs, and none of the probe definitions use motorized zoom????? What gives? Is this a special extra money option? Nothing I see will allow me to use the zoom, but the joystick pendant has + and - zoom buttons, so it clearly supports it.

Anyone have any ideas?! (Beyond calling hexagon....service/tech support seems much less willing to talk/help without a big payment up front...and I really just want the config files....not a ton of support)

You can look at the vision manual here, there are many informations about calibration, machine option tabs... :
ftp://ftp.wilcoxassoc.com/docs/v2010manual/

So, the manual didn't really help with the issue, but it did get me thinking about the error message. It says out of sequence, as if it thinks it moved, despite seeing no motion. What motion? Its gotta be zoom. PC-DMIS won't let me test zoom though. I do have a program from the QC5000 controller card. Well, that program also won't zoom, which means I'm likely on to something.

I see that for zoom in the qc5000 program, it has options for "Legacy", "Open Loop Stepper", "Closed Loop Servo", and "Closed Loop Stepper". Looking at the zoom mechanism on the machine itself, it sure looks like there is some sort of position encoder, though I couldn't tell you what sort (so I assume closed loop), and I'm not removing it to find out! (Don't need to have to calibrate that too!) Seeing that stepper is an option, I decided to have a closer look at the motor. At first, when I moved it manually, I didn't feel any cogging, so I discounted it being a stepper motor, however, this time, I noticed the sound. It sounds like a stepper through a gearbox. So, what the heck, I try setting it to stepper. Suddenly, its holding position. In the open loop mode it will try to home, though it doesn't seem to do a good job.

So I'm fairly certain this is a stepper motor. Unfortunately, that's where my progress ends. I don't have a clue what the settings are supposed to be. I double checked the Tesa Directory in the Program Files and the cnc.ini file still shows servo for the zoom axis. I verified axis 4 was zoom by setting it to stepper in the PC-DMIS directory, and fired up PC-DMIS, which then powered the stepper. Regardless of that, none of the axes were marked as stepper. So I'm fairly certain someone at the company who owned this machine when it got the suspected surge, or the used machinery dealer overwrote the original settings. Worse, I found tools to open the ghost image dell distributed as a restore disk (let me tell you, finding ghostexplorer from a site that isn't sketchy is impossible! virustotal said the one I found was clean). No Tesa directory there. No other discs I received have it either, so I suspect I'm missing a disc. So unless someone has a Visio 300 dcc they're willing to send me some settings from, I think I'm out of luck without some help from hexagon. If anyone wants to help without responding publicly, an email address I check sometimes (not my main one, not going to post that here) is corrysjunk at gmail dot com (Still don't want that one to be picked up by basic web scrapers, though that pattern is probably programmed in most bots as well...)

Otherwise, I guess I'll see what I can get from Hexagon tomorrow. Who knows, maybe there is another CD that I can order as a "part"

So, I think I was definitely on to something....couldn’t get settings, so I figured it must be that it should be that simple. Running the zoom several times suddenly caused the stepper driver to fry, short circuit, and kill the fpga on the pci card (or well I was pretty sure). After getting a ludicrous quote to replace the card, no repair options, etc, I decided to buy a bga rework machine and replace the fpga myself. The short answer is success! I also replaced the stepper driver, and I can hear pcdmis home it now, so I think it’s all working. I have another issue now though before I can test the calibration, but I’ll post that separately. I think it’s a much easier issue

Well, I'm back. I actually replaced the FPGA and board driver, repaired the PCB, the whole shebang. Still no zoom. I checked the encoder off the zoom motor, nothing. So I called up faulhaber, and they got me a replacement! Tested it in a test harness, and it worked. Plugged it in, no worky. Turns out the ground wire in the harness was broken. No continuity end to end. So, I replace that, anmd magically I have encoder pulses, FINALLY! Trial and error in the qc5k program led me to settings for the zoom of "Legacy", max counts 58. My motor wires may be backwards, because this wasn't the original harness, so I had to hit the reversed, limits reversed, and all, but then, it would move in the qc5k program. So I transferred the settings to PCDMIS's CNC.INI file, and...….

let down.

PCDMIS still refuses to zoom. Still get the "Attempted to move outside of calibrated range. Please re-calibrate optics" when I try to zoom manually, and the auto calibration with the calibration slide behaves the exact same way.

Any techs troll this place? Come on, I have to be close. I have all the hardware functional. Its gotta be some stupid setting somewhere in PCDMIS!