Table of Contents

Creating and Using Alignments ....................................................................................... 1

Creating and Using Alignments: Introduction............................................................... 1

Alignment Overview ..................................................................................................... 2

Alignment Command Format ....................................................................................... 4

Start Alignment Command ....................................................................................... 5

End Alignment Command ........................................................................................ 5

Adding Lines ............................................................................................................ 6

Deleting Lines .......................................................................................................... 6

Conventions ............................................................................................................. 6

Description of the Alignment Utilities Dialog Box ......................................................... 7

Creating a 3-2-1 Alignment ........................................................................................ 20

Step 1: Measure the Alignment Features ............................................................... 20

Step 2: Level, Rotate, and Translate to the Features ............................................. 21

Step 3: Completing the Alignment .......................................................................... 22

About QuickAlign ....................................................................................................... 23

Using QuickAlign .................................................................................................... 23

QuickAlign Error Messages.................................................................................... 32

Degrees of Freedom for Features in QuickAlign .................................................... 33

Creating an Iterative Alignment.................................................................................. 35

Understanding Iterative Alignments ....................................................................... 36

To Create an Iterative Alignment............................................................................ 39

Description of the Iterative Alignment Dialog Box .................................................. 40

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 Table of Contents

Creating a Best Fit Alignment .................................................................................... 47

To Create a Best Fit Alignment .............................................................................. 47

Understanding Best Fit Alignments ........................................................................ 49

Description of the Best Fit Alignment Dialog Box ................................................... 62

Saving an Alignment .................................................................................................. 68

To Save an Alignment ............................................................................................ 69

Editing the Save/Alignment Command................................................................... 70

Recalling an Existing Alignment................................................................................. 71

To Recall an Alignment .......................................................................................... 71

Using an Alignment Inside Loops or Branches .......................................................... 73

Equating an Alignment............................................................................................... 75

To Change a Part's Position and Orientation ......................................................... 76

To Recover after Accidentally Moving a Part ......................................................... 78

Equating CAD to Measured Part Data ....................................................................... 79

Performing a Leapfrog Operation .............................................................................. 79

Measure Options .................................................................................................... 81

Number of Hits ....................................................................................................... 82

Half Relocation ....................................................................................................... 82

Datum Measurement Routine ................................................................................ 83

Available and Used Lists ........................................................................................ 83

Measure Marked .................................................................................................... 83

Measure All ............................................................................................................ 84

Results area ........................................................................................................... 84

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Creating and Using Alignments: Introduction

Accept .................................................................................................................... 85

Reset...................................................................................................................... 85

OK .......................................................................................................................... 85

Changing Alignment Nominal Values ........................................................................ 85

Updating Dependent Commands When the Alignment Changes .............................. 86

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Creating and Using
Alignments
Creating and Using Alignments:
Introduction
Once you have activated a tip and measured features, you can create a coordinate
system (or alignment). PC-DMIS provides you with a variety of tools to create and
manage coordinate systems. To access the tools that allow you to work with
alignments, select the desired menu options available from the Insert | Alignment
submenu.

The major topics in this chapter describe how to use these tools to effectively create
and manage alignments in your measurement routine. These topics include:

• Alignment Overview
• Alignment Command Format
• Description of the Alignment Utilities Dialog Box
• Creating a 3-2-1 Alignment
• About QuickAlign
• Creating an Iterative Alignment
• Creating a Best Fit Alignment
• Saving an Alignment
• Recalling an Existing Alignment
• Using an Alignment Inside Loops or Branches
• Equating an Alignment
• Equating CAD to Measured Part Data
• Performing a Leapfrog Operation
• Changing Alignment Nominal Values
• Updating Dependent Commands When the Alignment Changes

Bundle Alignments

If you have a Leica Laser Tracker configuration, you can also perform a Bundle
alignment. This special type of alignment is discussed in the PC-DMIS Portable
documentation.

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 Creating and Using Alignments

Alignment Overview
An alignment allows you to define your part's location and orientation in 3D space. It
allows your measuring machine to know where the part is located. A part without any
alignment has six degrees of freedom:

• Three degrees of rotation (about the X, Y, and Z axes)

• Three degrees of translation (origin in X, Y, and Z axes)

This diagram shows the six degrees of freedom in 3D space (x,y,z,u,v, and w)

Datum Reference Frame

A Datum Reference Frame (DRF) constrains the six degrees of freedom, fixing the part
in 3D space.

A part alignment represents the DRF specified on the drawing. The primary, secondary,
and tertiary datums define the DRF and identify the features to measure and use to
create the alignment.

• The three degrees of rotation are constrained by the I, J, K vector(s) of the datum
feature(s).
• The three degrees of translation are constrained by the X,Y,Z location(s) of the
datum feature(s).

LEVEL

Constrains two degrees of rotation such that the leveled axis matches the vector
of the selected feature.

This will always be the primary datum and must be a 3D feature with a vector.

Typical Features: Plane, Cylinder, Cone, or a constructed 3D feature.

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Alignment Overview

ROTATE
Constrains one degree of rotation about the leveled axis such that the rotated axis
matches the vector of the selected feature.

This will always be the secondary or tertiary datum and must be a 2D or 3D

feature with a vector.

Typical Features: Plane, Line, Cylinder, Cone, or a constructed 2D/3D feature.

You can also select any two-point type features to simulate a line that can be used
to rotate. These can be two points, two circles, two spheres, or a combination
thereof. The direction of the simulated line is based on the order of the selected
features.

ORIGIN
Constrains three degrees of translation (origin) in X, Y, and Z-axis.

This sets the origin on primary, secondary, and tertiary datums or as per drawing
requirements.

Typical Features: Any feature.

Alignment Tips:

• LEVEL first, ROTATE second, and then set the ORIGIN for the X, Y, and Z axes.
Never Rotate before Leveling!
• Always LEVEL before measuring 2D features (lines and circles).
• Always LEVEL and ROTATE before measuring points (measured point in X, Y or
Z-axis)
• There is no limit on the number of alignments saved in a measurement routine.
• You can use the SAVE ALIGNMENT command to save an alignment to a file.
This is typically done to create a fully automated measurement routine
dependent on a holding fixture for the part.

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 Creating and Using Alignments

1. Create a measurement routine that establishes an alignment on a

fixture, and then save the alignment to a file.
2. Create a measurement routine, RECALL the alignment file at the beginning
of the measurement routine and set it to run in DCC mode before
measuring the first feature.
3. During measurement routine execution, the CMM pauses, prompts the
operator to load part, then automatically measures the part (no manual
alignment).

• Right Hand Rule of Rotation - Point your right hand's thumb in the positive
direction of the axis you are rotating about (+X, +Y, or +Z). The direction your
hand naturally curls is the positive rotation about that axis. Negative rotation is
the opposite direction.

Alignment Command Format

All alignments appear in the following format in the Edit window in Command mode.
There will be slight variations that are explained more thoroughly in the following
sections.

A1=ALIGNMENT/START, RECALL:,LIST=YES/NO
ALIGNMENT/LEVEL,'feature_name'
ALIGNMENT/ROTATE,XPLUS,TO,feat_name,ABOUT,ZPLUS
ALIGNMENT/TRANS,XAXIS,feature_name
ALIGNMENT/TRANS,YAXIS,feature_name
ALIGNMENT/TRANS,ZAXIS,feature_name
ALIGNMENT/END

See "Conventions" for field rules.

Descriptions of the alignment commands are available at these locations:

• For the Start command, see "Start Alignment Command".

• For the End command, see "End Alignment Command".
• For the Recall option, see "Recalling an Existing Alignment".

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Alignment Command Format

• For the Level command, see "Level".

• For the Rotate command, see "Rotate".
• For the Translate command, see "Origin".

Start Alignment Command

The line that starts the alignment is:

ALIGN_ID=ALIGNMENT/START,RECALL:ID, LIST=YES/NO

Changeable fields:

Align_ID
This is the ID that the alignment will be stored as. The operator assigns the ID.
PC-DMIS assigns a default name if you do not specify an ID. Example: A1.

ID
ID is a previous internal alignment that will be recalled to start a new alignment.
Note that you can also use the USE_ACTIVE_ALIGNMENT keyword in this field
to cause PC-DMIS to use the active alignment instead of recalling a stored
alignment. This is useful when you use alignments with looping and conditional
branching. See the "Using an Alignment Inside Loops or Branches" topic.

You can use the USE_PART_SETUP keyword in this field to cause PC-DMIS to
use the transformation defined in the Part setup area of the Part/Machine tab in
the Setup Options dialog box. This was handled by leaving the ID field blank in
versions prior to version 2012. See the "Setup Options: Part/Machine tab" topic in
the "Setting Your Preferences" chapter.

LIST
Setting this field to YES or NO lets you determine whether or not PC-DMIS should
display the alignment ID in the Alignments list on the Settings toolbar for later
insertion in the measurement routine. The default setting is YES. Setting this field
to NO is useful if you have a lot of temporary alignments, and you don't want to list
all of them in the Alignments list on the Settings toolbar.

End Alignment Command

The Edit window command line for this option reads:

ALIGNMENT/END

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 Creating and Using Alignments

There are no changeable fields in this command. You must use this command
whenever you use the ALIGNMENT/START command.

Adding Lines
To add a line, do the following:

1. Place the cursor in the desired location and press the Enter key.
2. Type the word ALIGNMENT.
3. Press the Tab key.

PC-DMIS adds the new line depending on where the cursor is located:

• If the cursor is in the middle of a command, PC-DMIS creates a new line below
the current line.
• If the cursor is placed at the beginning of a command line, PC-DMIS places the
new line above the current cursor position.

The first new line always displays the minor command: LEVEL. To easily change this,
enter a new command. Additional lines that you create after the initial line display the
most recent command.

Deleting Lines
To delete a blank line, press the Down Arrow or Enter key. The line may also be
highlighted and deleted. (See "Command Mode Keyboard Functions" in the "Using the
Edit Window" chapter.)

Conventions
• All alignment text commands are in a macro type format with a start command
and an end command.
• The ALIGNMENT/START command is always the first line, and the
ALIGNMENT/END command is the last line of the alignment statement.
• All alignment functions sub-commands must be inside the start and end
commands. The supported sub-command types are:
• ALIGNMENT/LEVEL
• ALIGNMENT/ROTATE
• ALIGNMENT/ROTATE_CIRCLE

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Description of the Alignment Utilities Dialog Box

• ALIGNMENT/ROTATE_OFFSET
• ALIGNMENT/TRANS
• ALIGNMENT/TRANS_OFFSET
• ALIGNMENT/ITERATE
• ALIGNMENT/BF3D
• ALIGNMENT/BF2D
• ALIGNMENT/BFUSER
• In each "ALIGNMENT/" command (except "START" and "END"), the second field
allows you to change from one choice to another. All of the other operator-
dependent fields then change to represent the field that is currently active.

Description of the Alignment Utilities

Dialog Box

Alignment Utilities dialog box

When you select Insert | Alignment | New (or press F9 on an existing alignment
command), PC-DMIS displays the Alignment Utilities dialog box. This dialog box
provides a way for you to construct an alignment from the features that have been
measured up to that point in the measurement routine.

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 Creating and Using Alignments

An alignment is not complete until you select the OK button and PC-DMIS
updates the Active Alignment List box.

As long as the Alignment Utilities dialog box remains open, PC-DMIS indicates any
remaining unconstrained degrees of freedom by causing the XYZ origin symbol (or
alignment trihedron) to continually rotate about and translate in the direction of those
unconstrained axes in the Graphic Display window. Once the alignment is completely
constrained, PC-DMIS then displays the trihedron in a fixed location and orientation that
represent the alignment position:

Alignment trihedron

ID box

This box defines the identification for the current alignment. If you are creating a
new alignment, the alignment ID will default to a new name. To change the ID,
type a new value in this box and press TAB.

Recall list

The Recall list contains all the internal alignments that have been defined in the
measurement routine prior to this alignment. The alignment selected from this
Recall list acts as the start condition of the current alignment.

If you are creating a new alignment, the Recall list will display the alignment active
at the cursor's current location in the Edit window. If you have not defined any
alignment, or if the cursor location is before any defined alignments in the Edit
window, the STARTUP command is selected as the recalled alignment.

8
Description of the Alignment Utilities Dialog Box

You can recall any available alignment listed in the Recall list. Only alignments
created prior to the current cursor's position and certain predefined special cases
are available for selection from that list.

These special cases include:

STARTUP - You can recall the STARTUP alignment automatically defined at the
start of the measurement routine.

USE_ACTIVE_ALIGNMENT - See the "ID" description in the "Start Alignment

Command" topic for more information.

USE_PART_SETUP - See the "ID" description in the "Start Alignment Command"

topic for more information.

Alignment Sub-Command list

This list displays a summary of each of the sub-commands that make up the
current alignment block. This summary includes information such as the type of
alignment sub-command, axis direction, and feature or features used by the sub-
command to perform its rotation and/or translation.

Editing a Sub-Command

While you can edit any existing Level, Rotate, or Origin alignment sub-command
inside the Summary or Command modes of the Edit window, you can also edit an
existing sub-command by clicking on its entry in the sub-command list and making
the needed change. Once you select an item, the appropriate area of the
Alignment Utilities dialog box becomes available to edit. After you've edited the
item, click the related sub-command button (Level, Rotate, or Origin) to modify
the alignment.

For example, if you wanted to modify the feature to which the alignment was
leveled, you would select the "leveled to" item in the list. PC-DMIS will display the
current feature used for the leveling portion of the alignment, and then it would
make the Level button available.

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 Creating and Using Alignments

Simply select the new feature and axis, and click Level. PC-DMIS updates the
Alignment Sub-Command list to reflect your changes.

To deselect an item from the Alignment Sub-Command list, click on

that item a second time, or press the ESC key on the keyboard.

Delete

The Delete button deletes the currently-selected sub-command from the

Alignment Sub-Command list.

Best Fit

The Best Fit button opens the Best Fit dialog box. Use this dialog box to create
or edit Best Fit alignments. See the "Creating a Best Fit Alignment" topic.

Iterative

The Iterative button opens the Iterative Alignment dialog box. Use this dialog
box to create and edit Iterative alignments. See the "Creating an Iterative
Alignment" topic.

Available features list

10
Description of the Alignment Utilities Dialog Box

The Available features area displays all the available features in your
measurement routine that exist above the current cursor location. These are the
features available to your current alignment command.

You can also use the Graphical Hit Selection method to select inputs to
your alignment. For details, see "Graphical Hit Selection Method".

For a full description, see "Feature List box" under "Dialog Box Description" in the
"Navigating the User Interface" chapter.

The Search ID filters the list of features by the specified ID. Type the ID string,
and press TAB.

The Select last # box-selects the final 'N' features in the list, where 'N' is the
number you type. Type the number of features to select, and press TAB.

The Clear button clears the current feature selections from the list.

Level

The Level area establishes the orientation of the normal axis of the current
workplane.

To choose a feature to "level" to:

1. Select the feature to be used from the Feature List box.

11
 Creating and Using Alignments

2. Choose the axis to level to from drop-down list.

3. Click the Level button.

The Level button only becomes active if you first select a feature from the feature
list or an existing level sub-command (ALIGNMENT/LEVEL). If you select an
existing level sub-command, it will be modified to use the new feature selection;
otherwise, a new level sub-command will be created using the selected feature.

You may also specify the axis to be used in establishing the orientation by
selecting it from the drop-down list. The available options are:

ZPLUS
XPLUS
YPLUS
ZMINUS
XMINUS
YMINUS

After you click the Level button, the Alignment Utilities dialog box
changes the About list next to the Rotate button to automatically match the Level
button's axis direction.

The Edit window command line for this option reads:

ALIGNMENT/LEVEL,ZPLUS,'feat_id'

Changeable fields:
"ZPLUS"
This is a field that allows you to switch between the ZPLUS, XPLUS, YPLUS,
ZMINUS, XMINUS, and YMINUS fields in the Edit window. This field represents
the direction of the specified axis that the feature is leveled to.

"feat_id"
The alignment levels to the specified feature.
Example: PLANE1.

Rotate

12
Description of the Alignment Utilities Dialog Box

The Rotate area rotates the alignment to be parallel to a selected feature by a

specific manual offset angle or by an angle defined from a picked CAD surface or
edge.

PC-DMIS rotates the Rotate to axis around the alignment origin, about the
specified alignment axis (About axis). The Rotate to and About axes cannot be
the same axis.

The available options are:

ZPLUS
XPLUS
YPLUS
ZMINUS
XMINUS
YMINUS

Rotate to a Feature

To rotate to a measured feature:

1. Select the proper reference feature from the Feature List box in the
Alignment Utilities dialog box.
2. Specify the axis to rotate to in the Rotate to list.
3. Specify the axis to rotate about in the About list.
4. Click the Rotate button.

The Rotate button only becomes active if you first select a feature from the
feature list or select an existing rotate sub-command (ALIGNMENT/ROTATE). If
you select an existing rotate sub-command, it is modified to use the new feature
selection Rotate to axis and Rotate About axis; otherwise, a new rotate sub-
command is created using the selected feature and axis settings.

The Edit window command line for this option reads:

ALIGNMENT/ROTATE,XPLUS,to,'feat_id',about,ZPLUS

Changeable fields:
"XPLUS","ZPLUS"

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 Creating and Using Alignments

This is a toggle field that allows you to toggle between these fields in the Edit
window:

ZPLUS

XPLUS

YPLUS

ZMINUS

XMINUS

YMINUS

PC-DMIS will set this axis parallel to the specified input feature. It will then rotate
about the second axis.

"feat_id"
The alignment rotates parallel to the specified feature. Example: LINE1.

Rotate to a Line between Two Circles

To rotate to the line between two circles, select two circles in the Available
Features list instead of a single feature and then continue with the "Rotate to a
Feature" procedure described above.

The Edit window command line for this option reads:

ALIGNMENT/ROTATE_CIRCLE,ID, ID

Changeable fields: "ID"

This is one of the two ids to which to rotate.

Rotate by a Manual Offset Angle

The Offset angle box allows you to rotate the alignment by a specified angle
about a selected axis.

To rotate by an offset:

1. Select the axis to rotate about from the About list.

2. Type the desired angle in the Offset angle box.
3. Click the Rotate button.

14
Description of the Alignment Utilities Dialog Box

The Rotate button becomes active once you type a value in the Offset angle box
or select an existing rotate offset sub-command (ALIGNMENT/ROTATE_OFFSET).
If you select an existing rotate offset sub-command, it is modified to use the new
Offset angle value; otherwise, a new rotate offset sub-command is created.

If you click Rotate, and you have a feature selected and a value entered in the
Offset angle box, the software creates these two sub-commands:

• First, it creates a ROTATE command to the selected feature.

• Second, it creates a ROTATE_OFFSET command with a value from the
Offset angle box.

The Edit window command line for this option reads:

ALIGNMENT/ROTATE_OFFSET,'numeric_value',ABOUT,'AXIS'

Changeable field: "numeric_value"

This is the value the alignment will be rotated by in degrees of angle (for example;
-14.36). The rotation will be about the axis, perpendicular to the active workplane.
The rotation will be clockwise if the angle is negative and counter clockwise if the
angle is positive.

Changeable field: "axis"

This is the axis about which the alignment will be rotated.

If you don't select a feature, and you type in a rotation Offset angle value,
PC-DMIS follows the right-hand rule of rotation. PC-DMIS follows the convention to treat
both the negative and positive axes as positive. This means PC-DMIS always rotates
about the XPLUS, YPLUS, or YPLUS axis. It does this even if you select XMINUS,
YMINUS, or ZMINUS. Positive offset angle values go in the positive direction (counter-
clockwise), and negative values go in the negative direction (clockwise). The software
enables the Rotate to list when you select a feature that controls an axis that matches
the vector of the selected feature.

Rotate by a Picked CAD Surface or Edge

To rotate the alignment by an offset angle by means of picking a surface or edge

on the CAD model:

1. From the Rotate to list, select the axis to which you want the alignment to
rotate.

15
 Creating and Using Alignments

2. From the About list, select the axis about which you want the alignment to
rotate.

3. Click the Pick in CAD icon .

4. PC-DMIS enters a special CAD-selection mode where the other dialog
box controls are disabled until you either select a surface or edge from the
CAD model, or you cancel this mode by clicking the icon again.
5. Once in this CAD-selection mode, click on the desired CAD model's
surface or edge in the Graphic Display window to define the alignment
rotation offset angle.
6. If the initial CAD selection does not define a valid rotation direction, PC-
DMIS waits for a second CAD model selection and uses that with the first
picked item to define the rotation direction.

PC-DMIS supports picking planar features, axial features (cylinders, cones, and
lines), and point-type features (spheres, arcs, and ellipses).

For a given CAD feature selection, the following apply:

• If you pick a planar feature, the plane's normal is used as the rotation
direction.
• If you pick an axial feature, the feature axis is used as the rotation
direction. If the feature axis is parallel to the selected About axis, you
must select a second feature to define the rotation direction perpendicular
to the axis.
• If you pick a point-type feature, you must select a second feature to define
the rotation direction.
• If you picked two axial features to define the rotation direction, the axes of
the two features must be parallel.
• If the picked item cannot be used to define an offset angle, PC-DMIS
displays an error message and then lets you pick a different feature or
cancel the CAD-selection mode.
• If the resulting angle is 0, no offset sub-command is created.

The Edit window command line for this option is identical to the "Rotate by a
Manual Offset Angle" case described above.

Origin

16
Description of the Alignment Utilities Dialog Box

The Origin area moves the alignment origin to a specific feature location, by a
specific manual offset distance, or by a distance defined from a picked CAD
surface or Edge.

Move to a Feature

To move the alignment origin to a feature:

1. Select the feature to move to.

2. Choose the alignment axis direction or directions to move the origin by
selecting the appropriate check box or check boxes (X, Y, Z, or Auto).
3. Click the Origin button. The Auto check box chooses the axes to move
based on the feature type, the orientation of the feature, and the
workplane.

The Edit window command line for this option reads:

ALIGNMENT/TRANS,ZAXIS,'feat_id'

Changeable fields:
"ZAXIS"
This is Edit window field allows you to switch between the fields ZAXIS, XAXIS,
and YAXIS. This field represents the axis that the origin will be moved along to
match the input 'feat_id'.

"feat_id"
This is the feature the alignment will set the origin to, along the given axis.
Example: CIRCLE1.

Move by a Manual Offset Distance

To move the origin by a manually-specified offset distance:

1. Choose the alignment axis direction or directions to move the origin by

selecting the appropriate check box or check boxes (X, Y, Z, or Auto).
2. Type the desired value in the Offset distance box.
3. Click the Origin button.

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 Creating and Using Alignments

When you click Origin, if you have a feature selected, and you have a value
entered in the Offset distance box, the software creates two sets of sub-
commands:

• First, it creates a set of TRANS commands to translate to the selected

feature, based on the selection state of the X, Y, Z, and Auto check
boxes.
• Second, it creates a set of corresponding TRANS_OFFSET commands
using the value from the Offset distance box.

The Edit window command line for this option reads:

ALIGNMENT/TRANS_OFFSET,ZAXIS,'numeric_value'

Changeable fields:
"ZAXIS"
This Edit window field allows you to switch between the fields ZAXIS, XAXIS, and
YAXIS. This field represents the axis along which the origin moves. The distance
moved is based on the 'numeric_value'.

"numeric_value"
This is the value by which the alignment is offset (for example, 5.12). A positive
value moves along the defined axis in the positive direction. A negative value
moves in the negative direction.

Move by a Picked CAD Surface or Edge

To move the origin by an offset by means of picking a surface or edge on the CAD
model:

1. Choose the alignment axis direction or directions to move the origin by

selecting the appropriate check box or check boxes (X, Y, Z, or Auto).

2. Click the Pick in CAD icon .

3. PC-DMIS enters a special CAD-selection mode where the other dialog
box controls are disabled until you either select a surface or edge from the
CAD model or you cancel this mode by clicking the button again.
4. Once in this CAD-selection mode, click on the desired CAD model's
surface or edge in the Graphic Display window to move the alignment to
the picked item.

PC-DMIS supports picking planar features, axial features (cylinders, cones, lines),
and point-type features (spheres, arcs, ellipses).

For a given CAD feature and set of alignment axis directions:

18
Description of the Alignment Utilities Dialog Box

• If there is a unique solution point between the CAD feature and specified
alignment axis directions, PC-DMIS moves the alignment to that point as
allowed by the selected alignment axes (such as a single alignment axis
and a planar feature).
• If there is more than a single solution point, PC-DMIS moves the
alignment to the solution point nearest the current alignment location as
allowed by the selected alignment axes (such as two alignment axes and
a planar feature intersecting at a line).
• Marking the Auto check box behaves the same as selecting X, Y and Z.
• If the selected CAD entity cannot be used to define an offset, PC-DMIS
displays an error message and then lets you pick a different feature or
cancel the CAD-selection mode.
• If the resulting offset distance for a specific alignment direction is 0.0, no
corresponding offset sub-command is created for that direction.

The Edit window command line for this option is identical to the "Move by a
Manual Offset Distance" case described above.

Auto-Set Origin for Level/Rotate

The Auto-set Origin for Level/Rotate check box works together with the Level
and Rotate buttons. If it is selected when you select a feature and click Level or
Rotate, the same feature used to define the level or rotate sub-command is used
to automatically create one or more translate origin commands. If there are two
features selected (for a rotate command), only the first feature is used. The
translation commands are based on the current X, Y, Z, or Auto settings in the
Origin area.

Auto-align

The Auto-align button uses the currently-selected features to automatically create

the alignment sub-commands. The Auto-align button is active only when exactly
one, two, or three features are selected from the list of available features, and
there are no sub-commands currently defined for the alignment. Auto-align uses
the same algorithms as QuickAlign. Auto-align supports all valid combinations of
features selected.

For more information on QuickAlign, see "About QuickAlign".

CAD = Part

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 Creating and Using Alignments

The CAD = Part (CAD Equals Part) button moves and orients the part origin
defined by the alignment so that it is equal to the CAD origin. This option should
be used after a created alignment places the part origin and orientation at the
same location as the CAD origin and orientation. This can make it simpler to use
the CAD data to help inspect the part by displaying the measured data directly on
top of the CAD data.

To set the CAD equal to the part:

1. Measure features on the part or fixture.

2. Use the alignment options to create an alignment.
3. Select the CAD = Part button. After the CAD = Part button is selected for
a part, the Operation | Graphic Display Window | CAD Equals Part
menu item will be selected.

The CAD = Part button is only available if the alignment is at the very
end of the measurement routine. If there are other commands after the alignment,
PC-DMIS hides the button.

Creating a 3-2-1 Alignment

The information presented here describes the steps you'll need to take to create a
standard 3-2-1 alignment.

Click this icon from the Wizards toolbar to access PC-DMIS's 3-2-1
Alignment Wizard.

Step 1: Measure the Alignment Features

The first thing you will need to do is measure the features used to create the 3-2-1
alignment. A 3-2-1 alignment uses three standard feature types for its creation. The
numbers 3, 2, and 1 refer to the minimum number of hits you need to take on in order to
measure these features.

20
Creating a 3-2-1 Alignment

• Measure a Plane. The first feature is the leveling feature and should be a plane
composed of three hits. PC-DMIS will level the part to this feature. This defines
the origin and direction of the first axis (usually the Z axis).
• Measure a Line. The second feature is the rotation feature and should be a line
composed of two hits. PC-DMIS will rotate the part to this feature, orienting the
second axis. The second hit of this feature should be in the positive direction of
the axis, relative to your first hit. This feature defines the direction of the second
axis (usually the X axis) and the origin of the third axis (usually the Y axis).
• Measure a Point. The third and final feature is the origin feature composed of
just one hit. Since PC-DMIS creates the origin for this axis from your first two
features, the third point merely establishes the origin of the entire alignment. PC-
DMIS will translate the part to this feature, making it the X=0, Y=0, and Z=0
location.

Once you've measured the necessary features, you're ready to create your alignment.

Step 2: Level, Rotate, and Translate to the Features

This step uses the Alignment Utilities dialog box (Insert | Alignment | New) to level,
rotate, and translate your part to the features measured in the previous step.

1. Access the Alignment Utilities dialog box (Insert

| Alignment | New). Notice that the Feature list
shows all the possible features that can be used to
level, rotate, or translate the part.
2. From the Feature list, click on the plane feature
you created in the previous step. Once PC-DMIS
selects the feature, select the axis to which PC-
DMIS should level the part, and then click the
Level button. PC-DMIS will display a line of text
inside the Alignment Utilities dialog box
informing you of the feature and axis to be used in
the leveling process.
3. From the Feature list, click on the line feature you
created in the previous step. Once PC-DMIS
selects the feature, select what axis to rotate to
and what axis to rotate about, and then click the
Rotate button. Again, PC-DMIS displays the

21
 Creating and Using Alignments

feature and axis to be used for the rotation

process.
4. From the Feature list, click on the point feature
you created in the previous step. Once PC-DMIS
selects the feature, select the appropriate axis
check box to determine which axis (or axes) you
want to move to this origin feature, and click the
Origin button.

Alternately, you can select all three of the features from the Feature list and
click the Auto Align button to have PC-DMIS automatically level to the first feature
selected, rotate to the second feature selected, and translate the axes to the third
feature selected.

Now you're ready to complete the alignment creation process.

Step 3: Completing the Alignment

To complete the alignment:

1. Ensure that the information in the Alignment Utilities dialog box (Insert |
Alignment | New) is correct.
2. When you're ready, click the OK button. PC-DMIS closes the dialog box. If this
new alignment differs from the existing alignment, PC-DMIS displays a prompt
asking if you want to update affected commands in the Edit window to use the
new alignment (see "Updating Commands in Learn Mode" in the "Updating
Dependent Commands When the Alignment Changes" topic). If the alignment
doesn't change (or the change is too small to matter), PC-DMIS simply inserts
the alignment without displaying the prompt or updating any commands.
3. PC-DMIS inserts the commands for the alignment into the Edit window, and
graphically shows the alignment on the CAD model inside the Graphic Display
window.
4. You can edit the alignment's code at any time by using the techniques described
in the "Using the Edit Window" chapter.

22
About QuickAlign

About QuickAlign
QuickAlign is designed so you can create alignments from the Edit window with a single
click of a toolbar icon. You can select valid combinations of one, two, or three features
to create an automatic alignment. QuickAlign is based on datum precedence principles
as described in the GD&T ASME Y14.5.1M standard.

The alignment is based on certain rules described in the topics below. There is no
dialog box for this functionality. The alignment is automatically created directly in the
Edit window in both the summary and command modes.

Using QuickAlign
Measure the alignment features you want to use in the QuickAlign.

From the QuickCMM toolbar, click the QuickAlign icon , or select the Insert |
Alignment | QuickAlign menu item.

If no other user-defined alignment command exists, PC-DMIS automatically selects the

features and create the alignment depending on whether the measurement routine is in
startup mode or standard mode.

QuickAlign creates the alignment based on:

• Feature type
• Selection order
• Feature positions relative to each other

QuickAlign constrains the degrees of freedom (DOF) as explained below:

• The first feature constrains all available DOF possible for that feature type.
• If two or more features are selected, the second feature constrains all available
unconstrained DOF possible for that feature type.
• If three features are selected, the third feature constrains as many remaining
unconstrained DOF possible for that feature type.
• QuickAlign aligns the machine axes closest to the theoretical axis of the features
that determine the LEVEL and ROTATE.
• QuickAlign supports all valid cases of feature combinations for creating an
alignment.

PC-DMIS displays the DOF that are controlled by the alignment on the status bar.

23
 Creating and Using Alignments

For more information on constraining degrees of freedom, see the "Alignment

Overview" topic.

QuickAlign in Startup Mode

When you first create a measurement routine, it contains a STARTUP command with a
default alignment. For QuickAlign, the measurement routine is considered to be in
"startup mode" if it does not have any user-defined alignment commands.

If it is in startup mode, the following apply:

• You do not need to select any features to create the alignment but you can if you
desire.
• If you don't select features, QuickAlign automates the initial alignment creation by
using up to the last three features in the measurement routine.
• If you do select features, QuickAlign uses the features in the selected order. For
more information on feature selection, see the "QuickAlign Feature Selection"
topic.
• It recalls the STARTUP alignment automatically if the alignment constrains all six
DOF. The STARTUP alignment is the default empty alignment at the start of
every measurement routine. This means no extra features are added to the
dependency list.
• QuickAlign creates the initial manual alignment by "backfilling" partial alignments
for level and rotation where applicable. For information on backfilling, see the
"Alignment Backfilling for QuickAlign" topic.
• QuickAlign creates DCC features and a DCC alignment if the following conditions
are met:
o The Machine type supports DCC mode
o The alignment constrains all six degrees of freedom (DOF).
o The measurement routine is in Manual mode

For more information, on DCC alignment creation, see the "DCC Alignment
Creation for QuickAlign" topic.

You can have non-feature commands, like dimensions, assignments, and so

on, in-between the features used for the alignment.

An Example

Measure a plane, line, and a point.

24
About QuickAlign

From the QuickCMM toolbar, click the QuickAlign icon , or select the Insert |
Alignment | QuickAlign menu item.

QuickAlign searches up from the end of the measurement routine and collects the three
newest features to use in the alignment.

It then uses the collected features to automatically generate fully constrained manual
and DCC alignments.

25
 Creating and Using Alignments

Clearance moves or other moves points are not generated. To avoid collision
during probe motion, be sure to activate the ClearanceCube or insert MOVE/POINT
commands as needed. QuickAlign does insert an Operator comment (COMMENT/OPER)
to remind the operator to add all needed clearance avoidance commands.

Alignment Backfilling for QuickAlign

"Backfilling" means QuickAlign looks back in the measurement routine and creates
partial alignments as required in order to accurately handle probe compensation of any
non-3D feature.

Back-filling occurs if these conditions are met:

• The measurement routine is in startup mode and therefore doesn't have a user-
defined alignment.
• One or more selected features for the QuickAlign operation is a 2D feature, such
as a line, circle, or point.
• A feature before the selected 2D feature exists that controls two degrees of
rotation (LEVEL).

26
About QuickAlign

An Example

A. Measurement Routine before QuickAlign

B. Measurement Routine after QuickAlign
C. Back-filled alignment after PLN1
D. Back-filled alignment after LIN2
E. Final, fully constrained alignment

DCC Alignment Creation for QuickAlign

For measuring machines capable of DCC operation, QuickAlign can automatically

define a DCC alignment by duplicating the features and rough manual alignment
commands in DCC mode in order to get a more accurate alignment.

DCC alignment creation can occur if these conditions are all met:

• PC-DMIS is in startup mode.

27
 Creating and Using Alignments

• PC-DMIS is connected to a DCC-enabled machine.

• The measurement routine is in manual mode.
• The features you choose for the alignment fully constrain the six degrees of
freedom.

How the DCC QuickAlign Functionality Works

The QuickAlign DCC functionality does the following:

• Adds an operator comment command (COMMENT/OPER), to remind the operator

to add all needed collision avoidance commands.
• Adds a mode command to change to DCC mode (MODE/DCC).
• Copies all the feature commands used for the manual alignment, along with any
feature commands they depend on, and pastes them using the same name as
their original feature names, appended with "_DCC".
• If the manual features are auto features and the probe type used is a scanning
probe and the Use Scanning Strategies for Quick Align check box, from the
General tab of the Setup Options dialog box (Edit | Preferences | Setup) is
marked then the DCC mode features are created using the scanning strategy
defined in the .ipd (inspection plan defaults) file.
• Generates a DCC alignment command after each DCC feature that is a copy of
one of the original manual features used to define the final manual alignment.
The original manual feature is replaced with its DCC copy in the new DCC
alignment. The resulting DCC alignment commands constrain all six DOF. Each
generated DCC alignment command is named based on the last manual
alignment name appended with _DCC1, _DCC2, and so on (for example, if A3 is
the name of your manual alignment, and two DCC commands are generated
from that alignment, they appear as A3_DCC1 and A3_DCC2).
• Recalls the STARTUP alignment automatically if the alignment constrains all six
DOF. The STARTUP alignment is the default empty alignment at the start of
every measurement routine. This means no extra features are added to the
dependency list.
• Ensures that all constructed features in DCC mode are constructed using
features measured in DCC mode.
• Creates an alignment using QuickAlign with features similar to a manual
alignment but is measured and constructed in DCC mode.
• Combines the manual alignments and their associated feature commands into a
GROUP command named "MAN ALIGN".
• Combines DCC alignment and its associated features into a into a GROUP
command named "DCC ALIGN".

28
About QuickAlign

An Example

A. Measurement Routine before QuickAlign

B. Measurement Routine after QuickAlign
C. Manual alignment group
D. Manual alignment
E. Change to DCC mode
F. DCC alignment group
G. Copied feature commands
H. Final DCC alignments

QuickAlign in Standard Mode

If one or more user-defined alignments already exist in the measurement routine, the
measurement routine is considered to be in "standard mode".

In standard mode, the following apply:

• QuickAlign does not backfill partial alignments.

• QuickAlign does not automatically create a DCC alignment.
• If you don't select features, only the last feature is used to create the alignment.

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 Creating and Using Alignments

• To create an alignment with more than just one feature, you must select the
features from the Edit window.
• The alignment is added at the end of the measurement routine.
• The alignment is created based on the same principles as described in the
"QuickAlign in Startup Mode" topic.

An Example

Measure some features.

From the QuickCMM toolbar, click the QuickAlign icon , or select the Insert |
Alignment | QuickAlign menu item.

QuickAlign automatically uses the last feature in the measurement routine to constrain
all possible degrees of freedom for that feature type.

QuickAlign Feature Selection

You can tell QuickAlign to use features by selecting them from the Edit window.
QuickAlign uses these features in the order you select them and creates the alignment.

30
About QuickAlign

To select multiple features in the Edit window:

1. Press and hold Ctrl.

2. From the Edit window, click on each feature to use in the alignment. The selected
features are highlighted as you select them.

3. From the QuickCMM toolbar, click the QuickAlign icon , or select the
Insert | Alignment | QuickAlign menu item.
4. QuickAlign uses the selected features to create an alignment at the end of the
measurement routine.

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 Creating and Using Alignments

Be sure to select the features in the correct precedence order. If you select more
than three features, PC-DMIS disables QuickAlign.

An Example

QuickAlign Error Messages

If the set of feature commands does not form a valid alignment, the alignment is not
created. In addition, PC-DMIS shows one or more of these error messages:

• "Unsupported feature combination!" - This message means the selected

combination of features does not define a well-formed alignment.
• "<FEATURE> is invalid!" - This message means the feature represented by
<FEATURE> has errors in its definition; this usually occurs with a line measured

32
About QuickAlign

on a surface where the line's line direction vector and the surface's normal vector
are not perpendicular.
• "<FEATURE> is not valid as the alignment second feature!" - This message
means the feature represented by <FEATURE> cannot be used as the second
feature in the alignment, due to its vector direction or its origin location.
• "<FEATURE> is not valid as the alignment third feature!" - This message means
the feature represented by <FEATURE> cannot be used as the third feature in
the alignment, due to its vector direction or its origin location.
• "Alignment error!" - This message indicates a general QuickAlign or Auto-align
error.

If PC-DMIS creates the alignment, but it has problems with its degrees of freedom, PC-
DMIS shows one of the following warning messages:

• "<FEATURE> is not used. All DOFs constrained by first two features." - This
message means that all six degrees of freedom (DOF) are already constrained
by first two features used to define the alignment; so the third feature isn't used to
constrain any of the DOF.
• "Not all 6 DOFs constrained" - This message means that the three features used
to define the alignment, do not constrain the six DOF, even though PC-DMIS
creates a valid alignment.

• QuickAlign determines if an axial feature is in a given plane by

checking if the vector of the feature (such as a circle, cylinder, cone, or line) is
within +/- 5 degrees of the axis or vector of the primary feature.
• QuickAlign determines if an axial feature can be used for rotation by checking if it
is more than 45 degrees from the primary feature vector.

Degrees of Freedom for Features in QuickAlign

The Auto-align algorithms are based on GD&T datum precedence principles and the
native degrees of freedom (DOF) of each feature type.

DOF of Supported Features

The supported features are grouped into the following six DOF-based cases, detailed in
this table:

33
 Creating and Using Alignments

DOF Case Feature Types DOF Constraints

Planar Planes, 3D Widths R1 R2 T3

Axial Cylinder, 3D lines, Cones* R1 R2 T1 T2

2D Line Lines (on a surface), 2D Widths R1 T2

1D Point Vector Points, Round Slots*, Square Slots* T1

2D Points Circles, Ellipses*, Edge Points, Angle Points T1 T2

3D Points Spheres, Corner Points T1, T2, T3

* These features are treated differently in the QuickAlign algorithm:

• Cone features are treated as cylinders.

• Ellipses are treated as circles.
• Slot features (both round and square) are treated as one-dimensional vector
points with their surface normal vector pointing in the direction of the slot width.

Table Key:
R1 - Rotation DOF about the first coordinate axis
R2 - Rotation DOF about the second coordinate axis
T1 - Translation DOF in first coordinate axis direction
T2 - Translation DOF in the second coordinate axis direction
T3 - Translation DOF in the third coordinate axis direction

34
Creating an Iterative Alignment

Creating an Iterative Alignment

Iterative Alignment dialog box

When you click the Iterative button from the Alignment Utilities dialog box (Insert |
Alignment | New), PC-DMIS displays the Iterative Alignment dialog box. This dialog
box provides a way for you to three-dimensionally "best fit" the measured data to the
nominal points (or surfaces, if available).

The resulting iterative alignment coordinate system origin is approximately located at

and oriented with the CAD coordinate system, even if the set of features used is located
and oriented somewhere very different. This is much like an automotive system, in the
sense that all the feature on all the parts of the automobile's body are defined in terms
of a single global coordinate system, even if they are physically located or oriented far
away from that coordinate system. The CAD coordinate system serves the same
function for the iterative alignment as the car body's global coordinate system.

An iterative alignment requires at least three features to be measured. Certain feature

types, such as points and lines, have poor three dimensional locations. If one of these
types of features is selected, additional features are needed to provide accurate
measured data.

• The first set of features establishes the orientation of the normal axis of the
current workplane by fitting a plane through the feature centroids. At least three
features must be used in this section (LEVEL - 3 +).
• The next set of features rotates the defined axis of the workplane to the features,
fitting a line through the features. At least two features need to be used in this
section (ROTATE - 2 + ).
If no features have been marked, the alignment will use features from the LEVEL

35
 Creating and Using Alignments

section. (The two features used from the LEVEL section are the second and third
from last feature.)
• The last set of features translates the part origin to a specific location (SET
ORIGIN - 1 ).
If no features have been marked, the alignment will use the last feature from the
LEVEL section.

Understanding Iterative Alignments

To properly create your iterative alignment, first consider the information presented
here; these topics will help you to understand important aspects of iterative alignments.

Iterative Alignment Command Format

The Edit window command line for this option reads:
ALIGNMENT/ITERATE,'feat_id'
, PNT TARGET RAD=n, START LABEL=label, FIXTURE TOL = n, ERROR
LABEL=label
MEAS ALL FEAT=NO/ALWAYS/ONCE,
MAX ITERATIONS = n
LEVEL AXIS =axis, ROTATE AXIS=axis, ORIGIN AXIS=axis
LEVEL = id, id, id,...
ROTATE = id, id,...
ORIGIN = id,...

Changeable field: "feat_id"

These are the features that are used to do the iterative alignment. Currently, you
must select at least three different features for the calibration. If features support a
datum axis in more than one direction, such as circles or slots, you can specify
them in more than one datum axis. For example, you can use a circle to both
establish the level axis as well as the rotation axis. Typically, you can only use
measured points (including vector and surface points) to establish one datum axis.

PNT TARGET RAD = This option specifies the target radius value for the
measured point features used in the alignment. See "Point Target Radius" for
complete information.

START LABEL = PC-DMIS starts at the label specified here when remeasuring
alignment features. You must set MEAS ALL FEAT to ALWAYS for this to work.
See "Start Label" for complete information.

36
Creating an Iterative Alignment

FIXTURE TOL = This is the tolerance that PC-DMIS uses to compare measured
alignment features to their theoretical values. See "Fixture Tolerance" for
complete information.

ERROR LABEL = PC-DMIS goes to the label specified here when the fixture
tolerance level is exceeded. If you don't define a label, PC-DMIS generates an
error message showing the amount of error on each of the input features. See
"Error Label" for complete information.

LEVEL AXIS = PC-DMIS uses the LEVEL input features to set the orientation and
origin of the axis specified here. See "Level" for complete information.

ROTATE AXIS = PC-DMIS uses the ROTATE input features to set the rotation of
the axis specified here about the level axis. The origin of the axis specified here is
also set by PC-DMIS using the ROTATE input features. See "Rotate" for complete
information.

ORIGIN AXIS = PC-DMIS uses the ORIGIN input features to set the origin of the
axis specified here. See "Origin" for complete information.

MEASURE ALL FEATURES = This option either re-measures the input features
or automatically re-executes a portion of the measurement routine in DCC mode.
There are three possible settings for this option:

• NO - See "Point Target Radius" for complete information.

• ONCE - See "Meas All Once" for complete information.
• ALWAYS - See "Meas All Always" for complete information.

MAX ITERATIONS = This option determines the maximum number of iterations

that PC-DMIS performs for this iterative alignment. PC-DMIS only uses this value
if the Meas All Always check box is selected.

Iterative Alignment Rules

There are some general rules when doing an iterative alignment.:

PC-DMIS needs both the measured values and theoretical values for each of the
elements in the sets. The normal vectors for the first set of elements must be
approximately parallel. The one exception to this rule is if only three features are being
used in the set.

If measured points (VECTOR, EDGE, or SURFACE) are being used, then all three sets
of elements are needed (three features to Level, two features to Rotate, and one feature

37
 Creating and Using Alignments

to Set Origin) to define the alignment. Any feature type can be used, but three-
dimensional elements are better defined elements and therefore improve the accuracy.
Some of the possible 3D elements are sheet metal circle, slot, cylinder, sphere, or a
corner point.

The sheet metal circle, slot, or cylinder needs at least three sample hits.

The difficulty of using measured points lies in not knowing where to take the
measurement until after the alignment. This poses a problem as the points must be
measured before the alignment. Three dimensional elements, by definition for this use,
are elements that can be measured precisely the first time.

Further, if measured points (VECTORS, EDGE, or SURFACE) are being used, the
features in the ROTATE set must have normal vectors that are approximately
perpendicular to the vectors of the features in the LEVEL set. The features in the
ORIGIN set must have a normal vector that is approximately perpendicular to both the
vectors from the LEVEL set and the ROTATE set.

If measured points (VECTORS, EDGE or SURFACE) are being used as part of the set,
PC-DMIS may ask that they be re-measured if they were taken too far from the nominal
location. PC-DMIS first "best fits" the measured data to the nominal data. Next, PC-
DMIS checks to see how far off each measured point is. If the distance is greater than
the amount specified in the Point Target Radius box, PC-DMIS will request that the
point be re-measured. PC-DMIS in effect puts a cylindrical tolerance zone around the
theoretical location of each vector, surface, or edge point. The radius of this tolerance
zone is the point tolerance specified in the dialog. PC-DMIS will continue to re-measure
point features until all the measured points fall into 'tolerance'. The tolerance zone only
affects measured points.

A special capability of PC-DMIS allows the center point of a slot to slide up or down the
axis as needed. For this reason, an iterative alignment cannot converge when a slot is
used as part of the ORIGIN set. It is possible to use a slot as part of the ORIGIN set by
first constructing a point from the slot and then using that constructed point in the
ORIGIN set.

A slot is not recommended as part of the ORIGIN set of an iterative alignment.

Type of Feature
Minimum # of Features needed:
used:

38
Creating an Iterative Alignment

This method uses 3 DCC circles for the

Circle 3 circles:
alignment.
Line This feature type is not recommended.
Point 6 points: The points are used as a 3-2-1 alignment.
This feature type is not recommended as part of the ORIGIN
Slot
set.
Sphere 3 spheres: This method uses 3 spheres for the alignment.

To Create an Iterative Alignment

Click this icon from the Wizards toolbar to access PC-DMIS's Iterative
Alignment Wizard.

To create an iterative alignment:

1. Access the Alignment Utilities dialog box (Insert | Alignment | New).

2. Click the Iterative button. The Iterative Alignment dialog box appears. You will
use this dialog box to create the iterative alignment. See "Description of the
Iterative Alignment Dialog Box" if you need information about the dialog box.
3. From the Feature List box, select the first set of features (at least three features)
to be used in establishing the orientation of the normal axis on the current
workplane.
4. Verify that the Level option is selected.
5. Click the Select button.
6. Select with the mouse the second set of features (at least two features) to be
used in the rotation process.
7. Verify that the Rotate option is selected.
8. Click the Select button.
9. Select the final set of features (at least one feature) that indicate the desired
location of the part origin. (The same features may be used in more than one
process.)
10. Verify that the Origin option is selected.
11. Click the Select button.
12. Click the OK button. The Iterative Alignment dialog box closes.
13. Click the OK button on the Alignment Utilities dialog box to complete the
alignment. The dialog box closes. If this new alignment differs from the existing
alignment, PC-DMIS will display a prompt asking if you want to update affected

39
 Creating and Using Alignments

commands in the Edit window to use the new alignment (see "Updating
Commands in Learn Mode" in the "Updating Dependent Commands When the
Alignment Changes" topic). If the alignment doesn't change (or the change is too
small to matter), PC-DMIS simply inserts the alignment without displaying the
prompt or updating any commands.

Selecting the Level, Rotation, or Origin options after they've already been
assigned features will display the indicated input features for that option.

After this process is complete, PC-DMIS will three-dimensionally "best fit" the measured
data and display the new alignment in the Graphic Display window and in the Edit
window. See the "Iterative Alignment Command Format".

Description of the Iterative Alignment Dialog Box

The following describes the items included in the Iterative Alignment dialog box (Insert
| Alignment | New | Iterative button).

Level

The Level - 3 option in the Iterative Alignment dialog box (Insert | Alignment | New |
Iterative button) is used in conjunction with at least three features selected from the
Feature List box. This set of features establishes the orientation of the normal axis of
the current workplane by fitting a plane through the feature centroids.

At least three features must be used to level.

Rotate

The Rotate - 2 option in the Iterative Alignment dialog box (Insert | Alignment | New |
Iterative button) is used in conjunction with at least two features selected from the
Feature List box. This set of features rotates the defined axis of the workplane to the
features, fitting a line through the features.

40
Creating an Iterative Alignment

At least two features need to be used to rotate.

If no features have been marked, the alignment uses features from the LEVEL
section. (The two features used from the LEVEL section are the second and third from
last feature.)

Origin

The Origin - 1 option in the Iterative Alignment dialog box (Insert | Alignment | New |
Iterative button) is used in conjunction with one feature selected from the Feature List
box. This feature set translates (or moves) the part origin to a specific location

One feature must be used to set the origin.

If no features have been marked, the alignment uses the last feature from the
LEVEL section.

Select

The Select button in the Iterative Alignment dialog box (Insert | Alignment | New |
Iterative button) enables you to use selected features from the Feature List box to
perform the Leveling, Rotating, and translating (or moving) to the Origin operations for
an iterative alignment.

Meas All Once

41
 Creating and Using Alignments

If you select the Meas All Once check box in the Iterative Alignment dialog box
(Insert | Alignment | New | Iterative button):

• PC-DMIS remeasures all the input features at least once in DCC mode.
• The input features are measured in the order specified by the iterative alignment
command in the Edit window.
• PC-DMIS displays which feature is about to be measured in a message box.
• Before accepting the move, ensure that the probe can reach the indicated
feature(s) without colliding with the part.
• Stored moves found before or after each feature are not executed.
• After all the features have been measured at least once, PC-DMIS continues to
remeasure the features for measured point types of features and those points
that missed their Point Target Radius target (see "Point Target Radius").

Since their location never changes, PC-DMIS only measures circles once
while in this mode.

Meas All Always

If you select the Meas All Always check box in the Iterative Alignment dialog box
(Insert | Alignment | New | Iterative button), PC-DMIS remeasures (or re-executes) a
portion of the current measurement routine at least once in DCC mode. The portion that
is re-executed depends on the Start Label (for information, see "Start Label"):

With a Start Label

If you provide a start label, PC-DMIS re-executes in DCC mode from that defined label
to the ALIGNMENT/START command that contains the currently executing iterative
alignment command.

Without a Start Label

If you don't provide a start label, the following occurs:

• PC-DMIS begins the DCC re-execution from the first feature measured in the
measurement routine that is used by the iterative alignment command.

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Creating an Iterative Alignment

• If the first feature has any stored move points preceding it then PC-DMIS also
executes those move points.
• PC-DMIS continues the re-execution of the measurement routine commands
until the last measured feature used by the iterative alignment command.
• PC-DMIS does not execute any stored moves after this command.
• Once the re-execution finishes, PC-DMIS recalculates the alignment and tests
any measured input points to see if they are all within the tolerance radius
specified in the Point Target Radius value.
o If they are all in the target radius, the re-execution does not need to
continue, and PC-DMIS considers the iterative alignment command
complete.
o If any points missed the target area, the same portion of the measurement
routine is re-executed as described above.

Move Points and Meas All Always During First Execution

A move point contains an XYZ value to which the probe moves during execution. If you
mark Meas All Always but PC-DMIS is in manual mode then during the measurement
routine execution of the iterative alignment, PC-DMIS redefines all the move point
locations to be relative to the iterative alignment's coordinate system in which they are
executed. This only happens once, on the very first execution of the iterative alignment.
If you later add additional move points and then re-execute the iterative alignment, the
new move points are also redefined to be relative to the iterative alignment, similar to
the other move points.

Point Target Radius

Use the Point Target Radius box in the Iterative Alignment dialog box (Insert |
Alignment | New | Iterative button) to specify the target radius tolerance for measured
point features used as inputs in the alignment. Measured input points include the
following:

• Measured Points (MEAS/POINT)

• Auto Vector Point (AUTO/VECTOR)
• Auto Edge Point (AUTO/EDGE)
• Auto Surface Point (AUTO/SURFACE)
• Auto Angle Point (AUTO/ANGLE)

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 Creating and Using Alignments

While you can usually see the location needed to measure a circle on a part easily
enough, determining the exact location to measure a point on the surface isn't easily
done. Without any visual indicators telling you where to measure the point, it is difficult
to manually measure the point in an exact spot. The Point Target Radius specifies an
imaginary tolerance zone (or target) the size of the radius, around each point. This
allows you to take a manual hit anywhere within the indicated tolerance when you
execute the measurement routine. If the measured point does not fall within this zone,
PC-DMIS re-measures the point in DCC mode.

PC-DMIS attempts to re-measure the input features based on the selected check boxes
in the Iterative Alignment dialog box (see "Meas All Once" and "Meas All Always").

If you don’t select either the Meas All Always or Meas All Once check box (or if you
manually set MEASURE ALL FEAT=NO in the Edit window),

• PC-DMIS tries to calculate an alignment transform so that the measured datums

match the theoretical datums, and then it checks to see if any measured input
points missed their targets. If so, only these features are re-measured in DCC
mode.
• PC-DMIS displays a dialog box indicating the feature that is about to be
measured. This lets you ensure that the probe can reach the desired feature
without colliding with the part.
• Once all point features are in target, PC-DMIS considers the iterative alignment
command complete.
• If there are any measured point features that missed their targets, PC-DMIS
continues to re-measure these features until they are in target.

Be careful not to set the vector Point Target Radius value too small (for
example 50 microns ). Many CMMs are unable to accurately position the probe to touch
each measured point on a minuscule target. A better choice is a tolerance of about .5
millimeters. If the re-measurement continues indefinitely, increase the value.

Fixture Tolerance

The Fixture Tolerance box in the Iterative Alignment dialog box (Insert | Alignment |
New | Iterative button) enables you to type a fitting tolerance value against which PC-
DMIS compares feature elements making up the iterative alignment to their theoretical
values.
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Creating an Iterative Alignment

If after fitting the measurement values to the theoretical values, one or more of the input
features have an error along their assigned datum axis that exceeds this tolerance
value, PC-DMIS automatically goes to the error label (if one exists). See "Error Label".

If you don't provide an error label, PC-DMIS displays an error message showing the
errors along each of the datums. You will have the choice to accept the datum as it is
and continue with the rest of the measurement routine, or to cancel the measurement
routine execution.

PC-DMIS can only use the fixture tolerance value if you used more than the minimum
number of points needed to create the feature. For example, if you are measuring a
plane, the minimum number of points needed for that plane is usually three points.
However, if you wanted to use the fixture tolerance value, you would need to measure
at least four points. If you use only three points, then only one solution exists, and PC-
DMIS cannot adjust or re-iterate.

Max Iterations

This box in the Iterative Alignment dialog box (Insert | Alignment | New | Iterative
button) determines the maximum number of repetitions that PC-DMIS performs when
creating the iterative alignment. PC-DMIS only uses this value if the Meas All Always
check box is selected.

Start Label

The Start Label box in the Iterative Alignment dialog box (Insert | Alignment | New |
Iterative button) allows you to define a label that PC-DMIS execution moves to when
remeasuring iterative alignment features. It remains disabled until you mark the Meas
All Always check box.

For information on how the Start Label works with Meas All Always during execution,
see the "Meas All Always" topic.

For more information on labels, see "Using Labels" in the "Branching by Using Flow
Control" chapter.

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 Creating and Using Alignments

Error Label

Use the Error Label box in the Iterative Alignment dialog box (Insert | Alignment |
New | Iterative button) to define a label that the measurement routine flow will go to if
the error in matching the measured level, rotate, and origin datum features to their
corresponding theoretical features exceeds the fixture tolerance level in the Fixture
Tolerance box.

If you supply the minimum number of inputs for each of the datum axes (three
for the Level datum, two for the Rotate datum, and one for the Origin datum), PC-
DMIS can fit the input feature measurement value to its theoretical values without
errors. In this case PC-DMIS doesn't really need the fixture tolerance. If you supply
more than the minimum number of inputs for any of the defined datums, then either part
or fixture errors may make it impossible to fit the measurement values to the theoretical
values with less error then the supplied fixture tolerance.

If you don't define an error label, PC-DMIS will generate an error message displaying
the amount of error for each of the datum features, giving you the option to cancel or
continue execution with the datums as they are.

To create a label, see "Using Labels" in the "Branching by Using Flow Control" chapter.

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Creating a Best Fit Alignment

Creating a Best Fit Alignment

Best Fit Alignment dialog box

When you click the Best Fit button in the Alignment Utilities dialog box (Insert |
Alignment | New), PC-DMIS displays the Best Fit Alignment dialog box. This dialog
box provides a way for you to "best fit" the measured data to the nominal points. With
the exception of the Vector method, which requires at least two points, you need at
least one point feature to create a best fit alignment.

To Create a Best Fit Alignment

To create a Best Fit alignment:

1. Access the Alignment Utilities dialog box (Insert | Alignment | New).

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 Creating and Using Alignments

2. Click the Best Fit button. The Best Fit Alignment dialog box appears. You will
use this dialog box to create the Best Fit alignment. See "Description of the Best
Fit Alignment Dialog Box" if you need information about the dialog box.
3. Select the features to be used out of the Available features list box. These will be
displayed in the Alignment features list box.
4. Define the orientation and degrees of freedom of the alignment by selecting
either the 2D, 3D or User Defined options in the Type drop-down list area. For a
2D alignment, also select the correct active plane from the 2D Plane drop-down
list.
5. Select the best fit type by choosing the appropriate options from the Best Fit
Method area.
6. To edit the weights of the features, double-click its weight value in the Alignment
features list. The weight value cell will turn into an inline edit field. Edit the value,
and then return or click outside the cell to finalize the change.
7. To set the point of rotation about a given feature, select the feature from the
Input List then click the Set button in the Rotate About area of the Advanced
tab. Alternately, a value can be entered into the Theoretical and Measured
boxes in the Rotate About area of the dialog box.
8. Click the OK button. The Best Fit Alignment dialog box closes.
9. Click the OK button on the Alignment Utilities dialog box. The dialog box
closes. If this new alignment differs from the existing alignment, PC-DMIS will
display a prompt asking if you want to update affected commands in the Edit
window to use the new alignment (see "Updating Commands in Learn Mode" in
the "Updating Dependent Commands When the Alignment Changes" topic). If
the alignment doesn't change (or the change is too small to matter), PC-DMIS
simply inserts the alignment without displaying the prompt or updating any
commands. Following execution, PC-DMIS will display a 3D Alignment Best Fit
Graphical Analysis in the Report window.

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Creating a Best Fit Alignment

Example of a Best Fit Alignment's Graphical Analysis in the Report

Window

A Sample of Best Fit Alignment Graphical Analysis in the Report Window

This graphical analysis of the 3D Best Fit alignment displays this information in
the Report window:

• Header - This contains various values used in the Best Fit alignment:
Method, Standard Deviation, Mean, Translation offsets, Rotation offsets,
Max iterations, Iterations.
• Vertical Axis - This shows the amount of deviation before and after the
alignment.

Red bars on bar graphs or red dots on circle graphs represent the
deviation, the 3D distance between the actual and the theoretical,
before the Best Fit alignment.

Green bars on bar graphs or green dots on circle graphs represent

the deviation, the 3D distance between the actual and the theoretical,
after the Best Fit alignment.

• Horizontal Axis - This displays the IDs of the points used in the
alignment.

Note that 3D alignments only use the bar graph.

Understanding Best Fit Alignments

A Best Fit alignment is an alignment that causes a set of measured points or a set of
actual feature centroids to match, as closely as possible to its nominal location or

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 Creating and Using Alignments

theoretical counterpart. In certain cases, it is also possible for a Best Fit alignment to
optimally match a set of points to a CAD curve or surface.

To understand the different Best Fit Alignment methods, see "The Best Fit Alignment
Methods".

About Exclusions

For 2D Vector Best Fit Alignments - Features with vector directions that are
perpendicular to the 2D best-fit plane are excluded from the alignment calculation.

For All Best Fit Alignments - Features that are skipped during measurement routine
execution are excluded from the alignment calculation.

If all features of the alignment are excluded, PC-DMIS displays an error message. If this
occurs during execution, PC-DMIS pauses the execution and gives you the option of
canceling execution. You can check the Best Fit Alignment dialog box (Insert |
Alignment | New | Best Fit button) to see if any of the alignment's features were
excluded due to invalid vectors or because they were skipped during execution.

The Best Fit Alignment Methods

This topic covers the available Best Fit Alignment solution methods when you define a
Best Fit Alignment.

The Best Fit Alignment minimizes deviations between measured point data and nominal
point data. The features you use in the alignment require correct nominal values in their
THEO fields.

The alignment methods below minimize the deviations in different ways:

Method 1: Least Squares Fit

Command Mode: LEAST_SQR

Description: The Least Squares algorithm aligns the two point sets. It does this
by transforming the measured points in such a way that it minimizes the sum of
the squared distances (between matching measured and nominal points). This is
the same as minimizing the average squared error. To understand how the Least
Squares alignment works, visualize a spring (of initial length zero) between each
measured point and its nominal counterpart. As the distance between the two
points increases, the springs stretch. The point set's final position when you
release it and let the springs act is the solution to the Least Squares alignment
problem.

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Creating a Best Fit Alignment

When to Use It: Use Least Squares to reverse engineer parts and to troubleshoot
manufacturing processes, when aligning to feature centers. These feature centers
come from regular features such as circles or cylinders.

Least Squares is the most common best fit type because it produces very
repeatable results. Least Squares is also used to troubleshoot the manufacturing
process, because it gives a better representation of all the point data, rather than
just the most extreme points (see the Min Max description below). Least Squares
is not ideal for complex surfaces where data is a set of points with unique vectors.
In that case, a Vector Least Squares fit is a better option.

Other Info: This is the default. Least Squares works with 2D, 3D, and User
Defined best fit alignments.

Algorithm: The least squares algorithm minimizes the sum of the squared lengths
of the deviations, meaning it minimizes the following mathematical function:

where are the weights.

Method 2: Vector Least Squares Fit

Command Mode: VECTOR_LST_SQR

Description: The Vector Least Squares fit is a kind of Least Squares fit, except
that it projects the error vectors onto the nominal vectors. It then uses these
projected distances in the Least Squares fit. A vector fit type allows points to
"slide" along the surface but discourages them from pulling away from the surface.
All errors are along the nominal vectors.

When to Use It: Use Vector Least Squares to reverse engineer parts and to
troubleshoot manufacturing processes, when aligning to surfaces. These surfaces
might be regular features, such as circles or cylinders, or they might be irregular
complex surfaces. The surface may be represented as a set of points with unique
vectors.

For instance, suppose the points are on the surface of a car hood. In this case,
motion along the surface is not as important as motion perpendicular to the
surface. Therefore, we use a vector fit to only measure deviations perpendicular to
the surface.

Other Info: This is also known as Projected Least Squares. Vector Least Squares
works with standard 2D and 3D best fit alignments, not User Defined best fit
alignments.
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 Creating and Using Alignments

Suppose you have a nominal point of 1,1,1 with a vector of 0,0,1, with
measured values of 4,2,0.95. With this fit, the software adjusts the measured data
to 1,1,0.95, and snaps it to the vector of 0,0,1.

Algorithm: The vector least squares algorithm minimizes the sum of the squared
projected deviations, where the deviations are projected onto the nominal vectors
, meaning it minimizes the following function:

Method 3: Min Max Fit

Command Mode: MIN_MAX

Description: A Min Max fit minimizes the maximum error (the largest distance)
among the features being fit.

When to Use It: Use Min Max to evaluate Position tolerances according to the
ASME and ISO standards, when tolerancing feature centers. These feature
centers come from regular features, such as circles or cylinders.

The Min Max algorithm applies simultaneous diametric tolerance zones to the
feature centers. Min Max fit types comply with ASME Y14.5 and ISO 1101.

Min Max fits are very sensitive to measurement uncertainty. A single bad
feature can affect the alignment results drastically.

The recommended input feature types for Min Max fits to evaluate position
tolerances are circles, spheres, cylinders, and cones. Min Max is not ideal for
complex surfaces where data is a set of points with unique vectors. In that case, a
Vector Min Max fit is a better option.

Other Info: Min Max works with 2D and 3D best fit alignments, not User Defined
best fit alignments.

Algorithm: The Min Max algorithm minimizes the maximum deviation length,
meaning it minimizes the following function:

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Creating a Best Fit Alignment

Method 4: Vector Min Max Fit

Command Mode: VECTOR_MIN_MAX

Description: The Vector Min Max fit is a kind of Min Max fit, except that it projects
the error vectors onto the nominal vectors. It then uses these projected distances
in the Min Max fit.

A vector fit type allows points to "slide" along the surface but discourages them
from pulling away from the surface. All errors are along the nominal vectors. A Min
Max fit minimizes the maximum deviation (the largest distance) among the
features being fit.

When to Use it: Use Vector Min Max to evaluate Profile tolerances according to
the ASME and ISO standards, when tolerancing surfaces. These surfaces might
be regular features such as circles or cylinders or they might be irregular complex
surfaces. Such surfaces include parts like blades and airfoils. The surface may be
represented as a set of points with unique vectors.

For instance, suppose the points are on the surface of a car hood. In this case,
motion along the surface is not as important as motion perpendicular to the
surface. Therefore, we use a vector fit to only measure deviations perpendicular to
the surface.

Make sure there is a good initial alignment of the machine to the part. Min Max fit
types comply with ASME Y14.5 and ISO 1101.

Other Info: Vector Min Max works with 2D and 3D best fit alignments, not User
Defined best fit alignments.

Algorithm: The Vector Min Max algorithm minimizes the maximum projected
deviation, so it minimizes the function:

2D Best Fit Command Line Format

The Edit window command line for the Best Fit 2D option reads:

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 Creating and Using Alignments

ALIGNMENT/BF2D,TOG1,TOG2,CREATE WEIGHTS=NO,TOG3,USE
SCALING=YES,n1,n2,n3,n4,n5
ITERATEANDREPIERCECAD=YES,TOLERANCE=n6,MAX ITERATIONS=n7,
CENTER OF ROTATION,MEAS_X,MEAS_Y,MEAS_Z,THEO_X,THEO_Y,THEO_Z
SHOWALLINPUTS=YES,SHOWALLPARAMS=YES
ID=

Available Fields:

"TOG1" This field allows you to switch between the available workplanes. The current
workplane should be displayed.

"TOG2" This field allows you to switch between the available types of best fits:
LEAST_SQR, VECTOR_LST_SQR, MIN_MAX, VECTOR_MIN_MAX. See "The Best
Fit Alignment Methods" for information.

CREATE WEIGHTS= This option lets you determine whether or not PC-DMIS creates
weights for the features used in the best fit alignment. Available options are YES or NO.
The created weights correspond to tolerances on the features used in the alignment.
See "Feature Weights".

"TOG3" This field determines the degrees of freedom for the 2D alignment. Available
options are: ROTONLY (rotation only), ROTANDTRANS (rotation and translation), and
TRANSONLY (translation only).

USE SCALING = This option is available if TOG2 is set to LEAST_SQR. If set to YES,
PC-DMIS computes a transformation (rotation and translation) and a scale factor to
optimally match nominal data to the scaled measured data. See "Description of the Best
Fit Alignment Dialog Box" where the Use Scaling check box is discussed.

n1,n2,n3= Translation in X,Y,Z

n4= The angle offset value.

n5=This is the scale factor. It only appears if USE SCALING is set to YES.

ITERATEANDREPIERCECAD= If set to YES, PC-DMIS will perform an Iterative Best

Fit alignment by piercing the CAD geometry and adjusting the feature nominals with
each iteration, using TOLERANCE= and ITERATIONS= values to control the result. If
set to NO, PC-DMIS does a single best fit alignment. See "Description of the Best Fit
Alignment Dialog Box" where the Use Scaling check box is discussed.

TOLERANCE=n6. This is the tolerance value for performing an iterate and repierce cad
operation. This only appears if ITERATEANDREPIERCECAD is set to YES.

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Creating a Best Fit Alignment

ITERATIONS=n7. This is the maximum number of times the best fit alignment algorithm
iterates when performing an iterate and repierce cad operation. This only appears if
ITERATEANDREPIERCECAD is set to YES.

CENTER OF ROTATION This field and the measured and theoretical XYZ values
associated with it, represent the center of rotation. They only appear if ROTONLY or
ROTANDTRANS is used for the TOG2 field. MEAS_X, MEAS_Y, and MEAS_Z are the
X,Y,Z values for the measured center of rotation. THEO_X, THEO_Y, and THEO_Z are
the theoretical X,Y,Z values for the theoretical center of rotation.

SHOWALLINPUTS= This option lets you determine whether or not the alignment code
block displays the feature inputs used to create the alignment. Available options are
YES or NO.

SHOWALLPARAMS= This option lets you determine whether or not the alignment code
block displays all the parameters for the feature inputs. Available options are YES or
NO.

If set to YES, then PC-DMIS displays this information for each input feature: Feature ID,
Feature Type, Dimension ID, Feature Weight, Feature Use.

For example, it might look something like this.

ID = CIR2,Circles,LOC12,2.000000,YES

If set to NO, then PC-DMIS will display only the ID of the input feature

ID = CIR2

ID= Each line began with "ID=" represents an input feature used in the alignment.

3D Best Fit Command Line Format

The Edit window command line for the Best Fit 3D option reads:

ALIGNMENT/BF3D,TOG1,CREATE WEIGHTS=YES,TOG2,USE
SCALING=YES,n1,n2,n3,n4,n5,n6,n7
ITERATEANDREPIERCECAD=YES,TOLERANCE=n8,MAX ITERATIONS=n9,
CENTER OF ROTATION,MEAS_X,MEAS_Y,MEAS_Z,THEO_X,THEO_Y,THEO_Z
SHOWALLINPUTS=YES,SHOWALLPARAMS=YES
ID=

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 Creating and Using Alignments

Available Fields:

"TOG1" This field allows you to switch between the available types of best fits.

"TOG2" This field allows you to switch between the available types of constraints for
the 3D alignment. Available options are: ROTONLY (rotation only), ROTANDTRANS
(rotation and translation), and TRANSONLY (translation only).

n1,n2,n3 - Translation in X,Y,Z.

n4 - Rotation in the XY plane

n5 - Rotation in YZ plane

n6 - Rotation in ZX plane

Note that the values for translation and rotation are relative to the current active
alignment, and the angles are always in degrees.

USE SCALING= This option is available if TOG2 is set to LEAST_SQR. If set to YES,
PC-DMIS computes a transformation (rotation and translation) and a scale factor to
optimally match nominal data to the scaled measured data. See "Description of the Best
Fit Alignment Dialog Box" where the Use Scaling check box is discussed.

n7= This is the scale factor. It only appears if USE SCALING is set to YES.

If seven number values are visible then the seventh number is the scale factor.

CENTER OF ROTATION This field and the measured and theoretical XYZ values
associated with it, represent the center of rotation. They only appear if ROTONLY or
ROTANDTRANS is used for the TOG2 field. MEAS_X, MEAS_Y, and MEAS_Z are the
X,Y,Z values for the measured center of rotation. THEO_X, THEO_Y, and THEO_Z are
the theoretical X,Y,Z values for the theoretical center of rotation.

ITERATEANDREPIERCECAD= If set to YES, PC-DMIS will perform an Iterative Best

Fit alignment by piercing the CAD geometry and adjusting the feature nominals with
each iteration, using TOLERANCE= and ITERATIONS= values to control the result. If
set to NO, PC-DMIS does a single best fit alignment. See "Description of the Best Fit
Alignment Dialog Box" where the Use Scaling check box is discussed.

TOLERANCE=n8. This is the tolerance value for performing an iterate and repierce cad
operation. This only appears if ITERATEANDREPIERCECAD is set to YES.

ITERATIONS=n9. This is the maximum number of times the best fit alignment algorithm
iterates when performing an iterate and repierce cad operation. This only appears if
ITERATEANDREPIERCECAD is set to YES.

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Creating a Best Fit Alignment

SHOWALLINPUTS= This option lets you determine whether or not the alignment code
block displays the feature inputs used to create the alignment. Available options are
YES or NO.

SHOWALLPARAMS= This option lets you determine whether or not the alignment code
block displays all the parameters for the feature inputs. Available options are YES or
NO.

If set to YES, then PC-DMIS will display this information for each input feature: Feature
ID, Feature Type, Dimension ID, Feature Weight, Feature Use.

For example, it might look something like this:

ID = CIR2,Circles,LOC12,2.000000,YES

If set to NO, then PC-DMIS will display only the ID of the input feature, like this:

ID = CIR2

ID= Each line starting with "ID=" represents an input feature used in the alignment.

Best Fit Alignment Types

You can have Best Fit Alignments solve 2D, 3D, or custom user-defined degrees of
freedom. Some important differences between these best fit alignment types are:

• A 2D Best Fit alignment requires an initial alignment to establish the 2D plane.

The alignment is created in the workplane defined by the current active
alignment.
• A 3D Best Fit alignment uses the raw (machine) data and correlates it to the
theoretical values. It does not require a previous alignment, but if the degrees of
freedom are set to rotation-only and a rotation center is not explicitly defined, it
uses the origin of the current active alignment as the rotation center.
• In most cases, a user-defined Best Fit alignment requires a previous alignment in
order to reliably establish the XYZ directions for the custom degrees of freedom.

Constraints for Best Fit Alignments

There are also constraints that can be applied to the Best Fit alignments.

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 Creating and Using Alignments

Constraints for 2D and 3D Best Fit Alignments

1. Rotate and Translate (default) - This allows the alignment full flexibility while
correlating the machine data to the theoretical values.
2. Rotate Only - This option restricts the alignment to rotation only, without
applying any translations of the rotation center. If no rotation center is defined,
the part coordinate system origin (0,0,0) is used as the rotation center.
3. Translate Only - This option restricts the alignment to translation only, without
applying any rotations.

Constraints for User-Defined Best Fit Alignments

The user-defined Best Fit alignment allows any degree-of-freedom combination other
than cases with two rotations (zero, one, and three rotations are allowed). It does not
support defining a rotation center. For relevant degree-of-freedom combinations, it uses
the part coordinate system origin (0,0,0) as the rotation center.

Feature Weights
The purpose of weights is to aid in simultaneous evaluation of Position or Profile
tolerances.

You can specify feature weights, or you can have PC-DMIS automatically generate
feature weights based on the tolerances' values.

Specified Weights

Each feature used as an input has an associated weight. The default value for these
weights is 1. You can modify the weights in the Edit window (View | Edit Window) or in
the Best Fit Alignment dialog box (Insert | Alignment | New | Best Fit button). The
values of these weights affect the resulting alignment. The larger the weight of a
particular feature, the more the resulting alignment will attempt to match the measured
value of that feature to its theoretical value. This association allows you to assign
priorities to the features in the alignment. If the weights of all the input features are
equal, then the features will be treated equally regardless of the value of the weight.

You can edit any of the weights by selecting the feature in the Alignment features list
and double-clicking the specific weight value. Edit the value as needed and then click
outside the field to set the new value. The new value will then be assigned to that
feature and used during the calculations.

Weights may also be assigned to each feature based on its associated dimension. If
there is no associated dimension, it will be assigned a default tolerance. Assign the

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Creating a Best Fit Alignment

weights by clicking the Set button. A composite weight for the feature is then computed
by multiplying the user-defined weights with the tolerance weights.

Tolerance-Generated Weights

For tolerance-based weights, a Min_Max fit reduces the percentage of the available
tolerance that each feature uses. The Least Squares fit reduces the "average" amount
of tolerance that all features use.

Because the generated weights are reciprocals of the tolerances, a feature with a
relatively small weight (or lower priority) corresponds to a large tolerance zone. This
gives it more freedom to move without affecting the other features. A feature with a
relatively large weight (or small tolerance zone) gets a high priority in the alignment
process.

Using Weights for Simultaneous Evaluation

1. Create some dimensions with the appropriate tolerances. Choose "no fit" for
these dimensions. Do not include these dimensions in the report. These
dimensions are for-reference-only. These are only present to inform the best-fit
alignment what the tolerances are.
2. Create a best-fit alignment that automatically creates weights on the toleranced
features. The best-fit alignment takes into account the tolerance sizes and any
applicable bonus as it creates the weights.
3. Create a second set of dimensions with the appropriate tolerances, using the
weighted best-fit alignment. Include these dimensions in the report.

Constructed Feature Sets and Curves as Best Fit Alignment

Inputs
When using a constructed feature set or a constructed curve as inputs to the Best Fit
alignment, a plus (+) sign will appear next to the feature ID in the Alignment features
list box in the Best Fit Alignment dialog box (Insert | Alignment | New | Best Fit
button). When you click on the plus (+) sign once, the features that make up that set or
curve will be displayed. Initially the weights for each feature will be the same as its
parent feature (the original set or curve).

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 Creating and Using Alignments

Feature Set Expanded to Show Features in the Set

Curve Expanded to Show Features in the Curve

You can edit the weight for each child feature of the set or curve by double-clicking the
current weight value and entering the new value as necessary. To change the weight of
all of the features in the set or curve, edit the weight on the feature set or the curve
itself. That weight will be transferred to all of its children.

Scans as Best Fit Alignment Inputs

When working with a scan, there is one extra component than when working with a
feature set. Scans are composed of basic scans. Each basic scan is composed of
individual points. When clicking a plus (+) sign next to a scan, it will expose all of the
basic scans associated with it. A plus (+) sign will appear next to each basic scan. By
clicking the plus (+) sign next to each basic scan, it will expose all of the individual
points associated with the basic scan. The weight for each point can be edited, the
weight of the basic scan (and all of its points) can be edited, or the weight of the scan
itself can be edited.

Tagged Features in a Feature Set or Scan

Also, you can tag individual members within a feature set so that they are not used. To
tag a member of a set to not be used in the best fit alignment, clear the check box to the
left of the feature in the Alignment features list box in the Best Fit Alignment dialog

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Creating a Best Fit Alignment

box (Insert | Alignment | New | Best Fit button). If a basic scan is un-checked, it and
all of its associated points will not be used in the calculations.

Alignment Center of Rotation

For 2D and 3D Best Fit alignments, you can specify a center of rotation in one of two
ways:

• Method 1: Select a feature from the Alignment features list in the Best Fit
Alignment dialog box (Insert | Alignment | New | Best Fit button). Next, click
the Set button. The theoretical and measured values are automatically entered
into the appropriate boxes in the Rotate About area.
• Method 2: If a specific coordinate is desired, manually provide the values by
typing the XYZ coordinate into the Theoretical and Measured boxes in the Best
Fit Alignment dialog box. The number values must be in an X,Y,Z comma-
delimited format in order to be valid. The values must be entered in terms of part
coordinates with regards to the active alignment trihedron.

If you do not specify a center of rotation, PC-DMIS uses the part coordinate system
origin (0,0,0) as the rotation center.

For user-defined Best Fit alignments, you cannot specify the rotation center. In this
case, the part coordinate system origin (0,0,0) is always used for degree-of-freedom
combinations where a rotation center is relevant.

Point Set to CAD Alignments

By default, PC-DMIS matches the measured points in your best fit alignment to the
original nominal point set. However, by enabling Iterate and Repierce CAD (see the
Iterate and Repierce CAD area discussed in "Description of the Best Fit Alignment
Dialog Box"), you can have the best fit alignment match the measured points to CAD
curves or surfaces instead. In this case, after the first best fit alignment is computed,
updated nominal points on the CAD curve or surface, corresponding to the transformed
measured points, are calculated. This process is repeated until convergence takes
place. This alignment method changes the theoretical values of the points.

If the re-pierce operation fails for all of the measured points included in the Best Fit
alignment, PC-DMIS will display an error message in the Warnings area and abort the
alignment calculation.

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Description of the Best Fit Alignment Dialog Box

Best Fit Alignment dialog box

The following features appear on all of the tabs in the Best Fit Alignment dialog box
(Insert | Alignment | New | Best Fit button):

Available features list

The Available features list contains a list of all the features in your measurement
routine before the alignment. For a full description, see "Dialog Box Description"
and "Feature List box".

Alignment features list

The Alignment features area lists the features selected for the best fit calculation
from the Available features list. You can sort each column by clicking on the
column header. The check box to the left of each feature ID enables or disables
the feature in the best fit calculation. If marked, the feature is used in the
calculation; otherwise, it isn't.

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If you select the Pause during execution check box (discussed below),
the alignment is automatically reset to include all features in the best fit calculation
during measurement routine execution.

If a calculated deviation is above the Deviation threshold value, the text for that
feature is displayed in red.

You can modify weights by double-clicking the specific Weight factor for the
feature in the Alignment Features list.

You can determine which axes are included in the calculation by double-clicking
the specific item in the Include XYZ column for the feature. This displays the
Include XYZ dialog box. Marking an axis includes the axis in the calculation.
Clearing an axis excludes it.

You cannot change the Weight and Include XYZ settings of a scan's
hits independent of their parent scan feature. Each hit uses the Weight and
Include XYZ settings of its parent scan.

Deviation threshold box

The Deviation threshold sets the maximum acceptable value for the calculated
deviation value. If a calculated deviation is above this threshold value, the text for
that feature is displayed in red in the Alignment features area. The measurement
units are the same as those defined in your system settings.

RMS Error
This displays the RMS Error value from the most recent alignment calculation.

Warnings area
The Warnings area displays any error messages from the most recent alignment
calculation.

Compute button
The Compute button updates the best fit alignment calculation using the current
features and settings.

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Setup Tab

Setup tab

The Setup tab contains the most common settings for defining a best fit alignment. The
following features are specific to this tab:

DOF (Degree of Freedom) area

DOF Check Boxes

The Tx, Ty, Tz, Rx, Ry, and Rz check boxes define which of the six degrees of
freedom (rotation about X, Y, or Z axis, and translation in the X, Y, or Z direction)
to include in the alignment. As the degrees of freedom are modified, the value of
the Type list (2D, 3D, 3D No Rotation, and so on) is automatically updated
according to the current settings. If the current combination of degrees of freedom
does not match any of the pre-defined cases, the type is set to User Defined.
Conversely, as the type is changed, the check boxes are updated to match.

Type

The 3D option causes the resulting alignment to be a 3D alignment that is both

Translated and Rotated.

The 3D No Translation option causes the resulting alignment to be a 3D

alignment that is Rotated but not Translated.

The 3D No Rotation option causes the resulting alignment to be a 3D alignment

that is Translated but not Rotated.

The 2D option causes the resulting alignment to be a 2D alignment that is both

Translated and Rotated in the selected 2D plane.

The 2D No Translation option causes the resulting alignment to be a 2D

alignment that is Rotated but not Translated in the selected 2D plane.

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The 2D No Rotation option causes the resulting alignment to be a 2D alignment

that is Translated but not Rotated in the selected 2D plane.

2D Plane

The 2D Plane list sets the plane in which to calculate a 2D alignment.

If Type is set to User Defined, PC-DMIS automatically selects the Least

squares option in the Best Fit Method area. The 2D plane list on this tab and the
Rotate About options on the Advanced tab are then unavailable.

The 2D Plane list is available only if you choose one of the 2D options from the
Type list. Available options are ZPLUS, XPLUS, YPLUS, ZMINUS, XMINUS, and
YMINUS.

The coordinate image dynamically updates based on the marked vector or

coordinate check boxes.

Best Fit Method area

The Best Fit Method area contains several methods that you can use to compute
the best fit alignment. For information on these methods, see "The Best Fit
Alignment Methods".

Iterate and repierce CAD area

Iterate and repierce CAD - If you select this check box, PC-DMIS performs an
Iterative Best Fit alignment after you click OK. This pierces the CAD geometry and
adjusts the feature nominals with each iteration using Tolerance and Max

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 Creating and Using Alignments

iterations to control the result. If this check box is cleared, PC-DMIS does a single
Best Fit alignment.

Tolerance - Type a tolerance value. PC-DMIS uses this tolerance when searching
for CAD surfaces to pierce. The measurement units for the tolerance is the same
as those used by the measurement routine. The new nominal point becomes the
CAD point closest to the actual feature, provided it is within this tolerance. If no
CAD surface is found within this distance from the actual feature, then that feature
is ignored in subsequent iterations.

Max iterations - This determines the maximum number of times the best fit
alignment algorithm iterates.

If the repierce operation fails for all of the features included in the Best Fit
alignment, PC-DMIS displays an error message in the Warnings area and aborts
the alignment calculation.

Advanced Tab

Advanced tab

The Advanced tab contains specialized settings for several less-common conditions.
The following are features specific to this tab:

Rotate About area

This area has two boxes that define the theoretical and measured center of
rotation. You can click Set to automatically populate these fields with X, Y, and Z
values from the feature selected in the Alignment features list, or you can
manually type your own X, Y, and Z values.

The Theoretical box contains the theoretical center of rotation for 2D and
3D best fit alignments.

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Creating a Best Fit Alignment

This Measured box contains the measured center of rotation for 2D and 3D
best fit alignments.

The Clear button clears both fields.

Use scaling check box

The Use scaling check box becomes available for 2D or 3D alignments when you
select the Least squares method. It is not available for alignments with specified
constraints.

When you use scaling, PC-DMIS computes a transformation (rotation and

translation) and a scale factor that optimally matches the nominal data to the
scaled measured data. The scaled alignment also scales all of the measured data
and subsequent measured features in the measurement routine, multiplying it by
the computed scale factor.

Once scaling has been applied to the measured data and features in a
measurement routine, it cannot be undone. Only mark Use scaling on in a single
alignment in the measurement routine.

You may find this useful, for example, in compensating for expansion or
contraction of a part due to temperature.

Create weights check box

If you select this check box, the software scales the values in the Weights column
located in the Alignment features list by the tolerance values of the dimensions
that control each feature.

If you clear this check box, the dimension tolerances are not factored into the
calculation. Only the weights you defined are included.

Pause during execution check box

If you select this check box, the software causes the measurement routine to
pause execution and display the Best Fit Alignment dialog box. This allows you
to examine the magnitude of the error in the alignment solution, identify any
features or scan hits that are bad, eliminate them from the alignment, recalculate,
and then repeat that process until you are satisfied with the alignment. When you
click OK, measurement routine execution resumes.

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This option is only available for portable measurement devices. For non-
portable machine types, it is hidden and ignored during measurement routine
execution.

Transforms Tab

Transforms tab

The Transforms tab displays the alignment transforms from the most recent best fit
alignment calculations. These transforms represent the cumulative state of the
measurement routine up to and including this best fit alignment. The following sections
are specific to this tab:

Machine to Part area - Displays the calculated Machine to Part transform values.

CAD to Part area - Displays the calculated CAD to Part transform values.

Machine to CAD area - Displays the calculated Machine to CAD transform

values.

Saving an Alignment
To save the current alignment in an external file that can be recalled by a different
measurement routine, select Insert | Alignment | Save. It also inserts a
SAVE/ALIGNMENT command into the Edit window.

The topics presented here describe the Save Alignment As dialog box and how to
save the alignment so that you can use it in other measurement routines.

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Description

• The Save in list and other familiar folder controls let you navigate to the directory
to which you will be saving the alignment.
• File name - Enables you to name the file of the alignment you are saving. By
default, the file name is based off of the Active Alignment box when the dialog
box opens.
• Save as type - Shows all the .aln files in the current directory. Only those files
with the alignment extension (*.aln) will be shown.
• Active Alignment - Defines the alignment name that will be saved to the
external alignment file. The alignment saved is the current (or active) alignment
in use based on the current insertion point in the Edit window.
o If the active alignment is from an ALIGNMENT/START command, it will
display the alignment’s name.
o If it is from a RECALL/ALIGNMENT, EXTERNAL command, it will display
the external filename without the ".aln" extension.
o If it is from a RECALL/ALIGNMENT, INTERNAL command, it will display
the name of the recalled internal alignment plus ‘:INTERNAL’.
• Inches or Millimeters - Sets the alignment to be saved with this type of
measurement unit.
• Machine to Parts - Stores only the machines to parts transformation matrix.
• Both - Stores both the CAD to parts transformation matrix and the machine to
parts transformation matrix.

To Save an Alignment
Note that you only need to save the alignment using the following procedure if the
alignment is going to be recalled into a different measurement routine. All alignments
are automatically saved when used within a measurement routine.

To save an alignment:

1. Select Insert | Alignment | Save. The Save Alignment As dialog appears.

2. Type an alignment name (maximum ten characters) in the File name box.
3. Select either the Inches or Millimeters option to save the alignment as either
inches or millimeters, respectively. The default unit of measurement for any
alignment will be the same unit of measurement used by the measurement
routine for which the alignment was created. To use an alignment in a different
measurement routine, it is not necessary that the alignment's units of
measurement be saved in the units type of the new measurement routine. The
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alignment will automatically convert to the same units as the new measurement
routine (For information on recalling an alignment, see "Recalling an Existing
Alignment").
4. Select either the Machine to Parts or Both option. Select Both to store both the
machine-to-parts and the CAD-to-parts transformation matrices. Select Machine
to Parts to store only the machine-to-parts transformation.
5. Click the Save button.

You must provide a file name in order to save. The only file name extension permitted is
".aln". If you don't type a valid name for the alignment file, clicking Save will not close
the dialog box.

The alignment can be saved to any directory. However, to use the saved alignment file
in a measurement routine, it must be saved the same directory as the measurement
routine or in the user-specified Recall Directory.

Whether you choose the Machine to Parts option or the Both option depends on the
following:

• If the part alignment origin matches the CAD origin, then it is not necessary to
include the CAD to Part transform. Either option will work.
• If the part alignment origin differs from the CAD origin in either location or
orientation, it is necessary to include the CAD to Part transform. Choose Both.
• If the measurement routine does not include a CAD model, there is no need to
include the CAD

The Edit window command line for this option reads:

SAVE /ALIGNMENT,filename, TOG1

TOG1
This toggle field switches between BOTH and MACHINETOPARTS. Select BOTH to store
both the machine to parts and the CAD to parts transformation matrices. Select
MACHINETOPARTS to store only the machine to parts transformation.

Editing the Save/Alignment Command

You can edit the SAVE/ALIGNMENT command by placing the mouse on the command
line and pressing F9.The Save Alignment As dialog box opens. You can use this
dialog box to edit all the settings for the alignment (file name, units, saved
transformation matrix) and then save the changes as a new or existing alignment file.
Once you make your changes, and click Save, PC-DMIS saves the alignment file and
applies the changes to the Edit window's SAVE/ALIGNMENT command.

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See the "Saving an Alignment" topic for a description of the dialog box.

Recalling an Existing Alignment

The Insert | Alignment | Recall menu option recalls an alignment that was previously
created in the current measurement routine (Internal Alignment) or saved from another
measurement routine (External Alignment). You can also recall an alignment using the
Alignment list on the Settings toolbar. For information, see the "Settings Toolbar"
topic.

This command can only be inserted outside an alignment block.

The Alignment Block is the block of text in the Edit window that defines the alignment. It consists
of the ALIGNMENT/START command and ends with the ALIGNMENT/END command.

The Recall button in the Alignment Utilities dialog box (Insert | Alignment |
New) also enables you to recall an existing alignment, but it only enables you to recall
alignments previously created in that measurement routine (internal alignments).

Before an alignment can be recalled to another measurement routine, you must save it
to a folder with the Insert | Alignment | Save menu option. For information on how to
do this, see "Saving an Alignment".

If the alignment you want to recall has different units of measurement than the current
measurement routine, its measurement units are automatically converted to the units of
measurement of the current measurement routine.

All recall external alignment commands re-load their external alignment file
when the measurement routine is first opened. During this process, if the new alignment
transforms differ from the existing alignment, PC-DMIS displays a prompt asking if you
want to update affected commands in the Edit window to use the new alignment. For
more information, see "Updating Commands When Loading a Measurement Routine" in
the "Updating Dependent Commands When the Alignment Changes" topic.

To Recall an Alignment
To recall an alignment using the Recall menu or Alignment Utilities dialog box:

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1. To access the Select Alignment dialog box, select Insert | Alignment | Recall;
or access the Alignment Utilities dialog box (Insert | Alignment | New) and
click the Recall button.
2. Type the 15 character (or less) saved alignment ID, or use the drop-down list to
select the desired alignment.
3. Click OK to insert the recall command into the Edit window
(RECALL/ALIGNMENT).

To recall an alignment using the Settings toolbar (View | Toolbar | Settings):

1. Use the Alignment list in the Settings toolbar and select the desired alignment.
2. PC-DMIS inserts the recall command into the Edit window
(RECALL/ALIGNMENT).

Recall Alignment Command Line Format

The Edit window command line for this option reads:

RECALL/ALIGNMENT, INTERNAL, 'align_id'

RECALL/ALIGNMENT, EXTERNAL, FILE_NAME

This command does not need to be bounded by the ALIGNMENT/START or

ALIGNMENT/END commands.

Code Used to Recall an Internal Alignment

RECALL/ALIGNMENT, INTERNAL, 'align_id'

align_id
This is the internal alignment that will be recalled from within the current
measurement routine.

Example:

RECALL/ALIGNMENT, INTERNAL, A1

Code Used to Recall an External Alignment

RECALL/ALIGNMENT, EXTERNAL, FILE_NAME

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Using an Alignment Inside Loops or Branches

FILE_NAME
This is the file name used for the saved external alignment, minus the .aln
extension. If you type a non-existent filename, PC-DMIS will display a warning
message letting you know that it could not find the alignment.

Example:

RECALL/ALIGNMENT, EXTERNAL, FIXTURE1

Using an Alignment Inside Loops or

Branches
PC-DMIS facilitates changing alignments inside a measurement routine that uses
looping or conditional branching by using the USE_ACTIVE_ALIGNMENT keyword
following the RECALL: text within your ALIGNMENT/START command. This keyword
lets you recall the active alignment.

If you have an alignment command inside a loop, and the loop uses
offsets, you must define all axes for that alignment. Additionally, the alignment
inside the loop must use features measured inside the loop.

The USE_ACTIVE_ALIGNMENT keyword also displays the name of the active alignment
within parentheses. So, if the active alignment was A3 during the last execution, the
keyword shows the following after execution:

USE_ACTIVE_ALIGNMENT(A3)

PC-DMIS uses the active alignment name for different purposes depending on whether
PC-DMIS is in learn or in execute mode.

• In learn mode, changing the alignment name in parentheses does not have any
bearing on the actual active alignment used or displayed during execution. In
learn mode this name is merely used as a tool for you to visualize different
scenarios that may occur during execution. You can visualize what may occur by
changing the active alignment in parentheses and watching the trihedron move to
that alignment's coordinate system in the Graphic Display window.
• In execute mode, PC-DMIS determines which alignment is active based on the
last executed alignment. This is dependent on any branching and looping that

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occurred during execution. After execution, the actual alignment which was
active during the last execution is displayed in parentheses.

Also, the alignment name in parentheses is now saved with the measurement routine.
When opening a measurement routine created prior to PC-DMIS 2010 MR2, the
information that appears in parentheses is dynamically populated by PC-DMIS as it
searched for alignments above the alignment with the USE_ACTIVE_ALIGNMENT
setting. This happens regardless of commands that may affect measurement routine
flow during execution, such as looping or branching commands.

Measurement Routines that have been imported from a DMIS file into PC-
DMIS do not support the functionality of showing the alignment name in parentheses,
even if you save the file as a new measurement routine.

USE_ACTIVE_ALIGNMENT Example

If you look at the ALIGNMENT/START command line in Command mode, you'll see that
the field immediately following the RECALL: text tells the measurement routine to use a
stored starting alignment first. In the following example, alignment D_1 starts with the
alignment from D_0 and then executes a 45 degree rotation about ZPLUS:

D_1=ALIGNMENT/START,RECALL:D_0, LIST= YES

ALIGNMENT/ROTATE_OFFSET,45.0,ABOUT,ZPLUS
ALIGNMENT/END

However, if you use the USE_ACTIVE_ALIGNMENT keyword instead, you can cause
PC-DMIS to rotate 45 degrees from the active alignment:

D_1=ALIGNMENT/START,RECALL:
USE_ACTIVE_ALIGNMENT(D_0), LIST= YES
ALIGNMENT/ROTATE_OFFSET,45.0,ABOUT,ZPLUS
ALIGNMENT/END

When you use this keyword for an alignment inside a loop:

• The first time through the loop the active alignment will be the last executed
alignment preceding the loop.
• Additional times through the loop the active alignment will be itself and will rotate
a further 45 degrees from the previous time through the loop.

For information on looping, see the "Creating Generic Loops" topic in the "Branching by
Using Flow Control" chapter.

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Preferences that Affect USE_ACTIVE_ALIGNMENT

When you use the USE_ACTIVE_ALIGNMENT keyword, you should generally deselect
the Reset global settings when branching check box and select the Treat theo
values as if stored in part coordinates check box on the General tab in the Setup
Options dialog box (Edit | Preferences | Setup).

See the "Setting Your Preferences" chapter for information on specifying setup
preferences.

Equating an Alignment

Equate Alignment dialog box

The Insert | Alignment | Equate option provides the means to:

• Change the position or orientation of a part while retaining previous dimensional

information.
• Re-align the part and save previously measured data if the part is accidentally
bumped or moved during the inspection process.

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To Change a Part's Position and Orientation

Equate Alignment dialog box for Part moved on machine

For Equate Alignment to function properly, the features referenced in your new
alignment must be measured after you move your part. Those features must reside in
the measurement routine below the commands that are executed in the part's original
position and orientation (including the original alignment). Additionally, you should
reference all of the features for your new alignment in a single alignment block. The new
alignment should be fully constrained.

This command works with both regular alignment blocks (START_ALIGN/END_ALIGN

pairs) and external recalled alignments. The external alignment must be recalled using
the RECALL/ALIGNMENT, EXTERNAL command before it becomes available for use in
the dialog box.

Equate new alignment:

This list allows you to select the new alignment you are equating with your original
created alignment.

With original alignment

This list allows you to select a the previously created original alignment to which you are
equating the new alignment.

For example, to measure a dimension that references features on two sides of the part
that are not accessible from a single part orientation:

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1. Measure the alignment features on the first side of the part.

2. Create the original alignment.
3. Measure all required features that can be reached from the first orientation of the
part.
4. Move the part to its new position.
5. Measure the new alignment features. The origin must be the same and the axis
must be in the same direction as the axis of the alignment to which you are
equating. It is easiest to understand this if you imagine that the original origin and
axes' arrows are glued onto the part before moving it. The new alignment places
the origin and axes' arrows in the same position with respect to the part.
6. Select the Insert | Alignment | Equate menu option. The Equate Alignment
dialog box appears.
7. In the Equate Type area, select Part moved on machine. Note that when
editing an existing Equate alignment command, the Equate Type area is
disabled.
8. In the Equate new alignment list, select the new alignment.
9. In the With original alignment list, select the original alignment.
10. Click the OK button to insert the new EQUATE alignment command into the
measurement routine. The CAD model won't move relative to the alignment axes,
but the measured values will move once PC-DMIS executes the equate
alignment.

The Edit window command line for this option reads:

EQUATE/"name1"TO ALIGNMENT,"name2"

Note about Clearance Planes

After equating the new alignment, any existing clearance planes continue to use the
same "relative" plane from the previous alignment. This means after you've moved your
part, you should define new clearance planes to avoid incorrect clearance plane moves.

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To Recover after Accidentally Moving a Part

Equate Alignment dialog box for Part bumped

For this operation to function properly, the alignment should be fully constrained.

This command only works with regular alignment blocks (START_ALIGN/END_ALIGN

pairs).

Re-measure alignment

This list allows you to select the existing alignment to remeasure to update all the
machine coordinates of the commands in the measurement routine.

If a part has been moved accidentally, do the following:

1. Select the Insert | Alignment | Equate menu option to open the Equate
Alignment dialog box.
2. In the Equate Type area, select Part bumped.
3. In the Re-measure alignment list, select the ID of the alignment you need to
remeasure.
4. Click OK to begin the remeasure process.
5. Re-measure the alignment features. When this finishes, all dimensional and
feature information are translated to the new position of the part. The CAD model
does not move relative to the alignment axes, but the measured values are
updated.

If you use this option, PC-DMIS does not insert a new command in the Edit window.

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Equating CAD to Measured Part Data

The Operation | Graphic Display window | CAD Equals Part menu option (or the
CAD = Part button in the Alignment Utilities dialog box) links CAD data to the
measured data. This option is only available after a created alignment places the part
origin/orientation at the same location as the CAD origin/orientation. PC-DMIS offers the
CAD EQUALS PART option in two areas (also see "CAD Equals Part" within the
Alignment option). Select this option and PC-DMIS will display the measured data on
top of the CAD data. It will use the CAD data to help inspect the part.

Once the CAD Equals Part option has been used on a measurement routine, the CAD
Equals Part menu option will be selected.

Performing a Leapfrog Operation

PC-DMIS does not support Leapfrog and Bundle Alignment commands used in
the same measurement routine.

Select Insert | Alignment | Leapfrog to display the LeapFrog / Relocation dialog box.
This menu option is disabled in Offline mode. You must be connected to a physical and
supported portable machine.

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LeapFrog / Relocation dialog box

The LeapFrog / Relocation dialog box allows you to move supported portable
machines in order to measure parts that are too large for your CMM. You should be
aware of machine accuracy limitations before using this method.

Currently, supported machines include Faro, Romer, and Garda.

Your LMS license or portlock needs to be programmed to support your portable

machine.

The basis for Leapfrog is to measure a series of features, and then after moving the
machine, re-measure the same features in the same order. This creates a
transformation and makes the machine behave as if it were in the same coordinate
system before the move.

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Performing a Leapfrog Operation

Prior to PC-DMIS version 4.2, Leapfrog transformation information was stored

in a separate file and was thereby independent of all measurement routines. This meant
the Leapfrog was still active in newly-created measurement routines and you had to
remove it by clicking the Reset button on the Leapfrog / Relocation dialog box. In
version 4.2 and later, however, this has changed. Leapfrog transformation information is
now stored with the measurement routine that used the Leapfrog operation; you no
longer have to remove the Leapfrog from new measurement routines.

PC-DMIS enters a Leapfrog command into the Edit window when you click the Accept
button.

The command line in the Edit window is:

LEAPFROG/TOG1, NUM, TOG2

TOG1: This first parameter in the Leapfrog command is a toggle field that relates to the
different types of measurement options that are available in the dialog box. These
include:

1. SPHERES (Measure 3 Spheres option)

2. PSETS (Measure 3 Point Sets option)
3. POINTS (Measure 3 Points option)
4. DATUMS (Measure Datums option)

There is also an OFF value for this parameter, in which case the other two parameters
do not appear. The OFF value turns off Leapfrog translation.

NUM: This second parameter in the Leapfrog command is the number of hits you want
to take. This corresponds to the Hits box in the LeapFrog / Relocation dialog box.

TOG2: This last parameter in the Leapfrog command is a toggle field that you can use
to switch between either a FULL or a PARTIAL Leapfrog. This parameter corresponds
to the Half relocation option in the dialog box.

When this command executes, PC-DMIS prompts you to take your hits. After all the hits
are taken, a Leapfrog translation is in effect.

Measure Options
The Measure options in the LeapFrog / Relocation dialog box (Insert | Alignment |
Leapfrog) enable you to select the method that PC-DMIS uses to perform the
translation comparison.

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• The Measure 3 Spheres option tells PC-DMIS to use spheres as the features for
translation comparison. This method uses the center of each measured sphere.
• The Measure 3 Point Sets option tells PC-DMIS to use the centroid of a set of
points. It is recommended that you use the bottom of an inverted cone with a
hard probe. This method is slightly more accurate than the spheres method and
much quicker for the operator. For information on how to create point sets, see
the "Creating Measured Feature Sets" topic in the "Creating Measured Features"
chapter.
• The Measure 3 Points option tells PC-DMIS to use only three points and is the
least accurate of the three methods.
• The Measure Datums option tells PC-DMIS to use existing datum features from
a measurement routine of your choice. Because the datum features are already
assumed to have been measured in your existing measurement routine, you only
need to measure them after relocating your machine.

Number of Hits
The Number of Hits box in the LeapFrog / Relocation dialog box (Insert | Alignment
| Leapfrog) enables you to specify the number of hits you wish to use for each feature.
Of course, this will not be used in the point method.

Half Relocation
The Half Relocation check box in the LeapFrog / Relocation dialog box (Insert |
Alignment | Leapfrog) lets you determine whether or not PC-DMIS performs a FULL
RELOCATION (FULL LEAPFROG) operation (if not selected) or performs a PARTIAL
RELOCATION (PARTIAL LEAPFROG) operation (if selected).

Relocation refers to moving the portable measuring machine to a new location.

• Doing a full relocation (clearing this check box) means you would need to
measure something before you move the portable machine and then re-measure
some or all of those items after moving the machine. Remeasuring allows PC-
DMIS to determine the new location of the machine.
• A half relocation (selecting this check box) means you move the portable
machine first and then measure the datum features.

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Datum Measurement Routine

This area in the LeapFrog / Relocation dialog box (Insert | Alignment | Leapfrog)
enables you to specify the measurement routine file to use as the datum program file.
This box becomes enabled when you click the Measure Datum Features option. You
can type the full pathway to the measurement routine (.PRG) file, or you can use the
Browse button to navigate through your directory structure and select one that way.

Once you select a file, the features available for use in the Leapfrog operation appear in
the Available list.

Available and Used Lists

The Available and Used lists in the LeapFrog / Relocation dialog box (Insert |
Alignment | Leapfrog) display, respectively, datum features that are available for use
or datum features that you have chosen to use in the Leapfrog operation.

Available List

When you select a measurement routine file to use in the Datum Program File area,
the available features from that file appear in the sortable Available list. You can then
assign features to the current Leapfrog operation by selecting them and then clicking
the >>> button. More information on the Feature list section can be found in the

Used List

Assigned features that appear in the Used list will be measured when you click the
Measure Marked or Measure All buttons in the order that they appear in the Used list.
You can remove them from the Used list by clicking the <<< button. You can change a
feature's order of execution by selecting a feature clicking the up or down arrow buttons.

Measure Marked
The Measure Marked button in the LeapFrog / Relocation dialog box (Insert |
Alignment | Leapfrog) only functions when you use the Measure datums option. It
allows you to measure any selected features from the Used list. PC-DMIS will use these
features in the Leapfrog operation. When you click this button, PC-DMIS displays the
Execution dialog box, prompting you to measure the selected features once you have
moved the CMM, not before.

The results box will display the 3D distance between the features taken before the move
and after the move of the CMM. If you find the results unsatisfactory then you may re-
measure the last set of features again as the button will now read Re-measure.

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After you move the CMM, there is not a way to revert to the previous alignment.
If the Leapfrog results are unsatisfactory after the Re-measure process, you must reset
the Leapfrog and restart the entire part inspection process by executing the
measurement routine from the initial alignment. The physical limitation of using a single
CMM device makes this condition possible for all relocation methods. You should take
great care during the execution of any relocation procedure.

Measure All
Similar to Measure Marked, the Measure All button in the LeapFrog / Relocation
dialog box (Insert | Alignment | Leapfrog) also opens the Execution dialog box.

• If you are using Measure 3 Spheres, Measure 3 Point Sets, or Measure 3

Points, then this dialog box will first prompt you to measure the three features
before prompting you to move the CMM. After moving the machine, you will be
prompted to re-measure the same features in the same order.
• If you are using Measure Datums, then the Execution dialog box prompts you
to measure all the datum features once you have moved the CMM, not before.

The results box will display the 3D distance between the features taken before the move
and after the move of the CMM. If you find the results unsatisfactory then you may re-
measure the last set of features again as the button will now read Re-measure.

If the re-measure process proves unsatisfactory, then you must reset the
leapfrog and start again from the beginning. This is a problem with all leapfrog systems
and should be remembered.

Results area
The Results area in the LeapFrog / Relocation dialog box (Insert | Alignment |
Leapfrog) shows the deviations between the machine's first position and its subsequent
position(s) by displaying the 3D distance between the features taken before the move
and after the move of the CMM.

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Accept
Once you have a filled out the Leapfrog / Relocation dialog box, you must click the
Accept button from the Results area before the leapfrog transformation will be used.
Clicking Accept will add the LEAPFROG command to the measurement routine. If you
don't click the Accept button but click the X in the upper-right corner or click OK first,
the constructed leapfrog translation will be lost.

Reset
The Reset button in the LeapFrog / Relocation dialog box (Insert | Alignment |
Leapfrog) removes any translation by adding a LEAPFROG/OFF command into the Edit
window.

OK
Clicking OK in the LeapFrog / Relocation dialog box (Insert | Alignment | Leapfrog)
closes the dialog box. If you click this button before you click the Accept button, the
dialog box will close without inserting the LEAPFROG command.

Changing Alignment Nominal Values

If you modify an alignment feature's theoretical values during execute mode, PC-DMIS
changes the CAD to Parts alignment. This means that features in your measurement
routine that come after the alignment, and are measured relative to the alignment
features, shift by the amount of the changed theoretical values.

If you select the Ignore CAD to Part check box on the General tab in the Setup
Options dialog box (Edit | Preferences | Setup), the CAD to Parts alignment does not
change when your alignment feature theoretical values change. The features below the
alignment are then measured in their same position. See "Ignore CAD to Part" in the
"Setting Your Preferences" chapter.

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You cannot use the Ignore CAD to Part functionality if you use Position
dimensions in your measurement routine.

You can also control how PC-DMIS handles your features' nominal values when you
update an alignment's theoretical values by using the
UpdateBelowChangedAlignmentDuringExecution registry entry in the PC-DMIS
Settings Editor. For additional information, see the "Modifying Registry Entries"
appendix.

Updating Dependent Commands When

the Alignment Changes
An alignment consists of two transforms:

1. Machine origin to Part origin (termed "Machine-to-Part")

2. CAD origin to Part origin (termed "CAD-to-Part")

If either of the transforms is modified, PC-DMIS displays a Yes/No message similar to

the following, letting you choose how the commands dependent on the alignment are
updated:

PC-DMIS:

External alignment file FIXTURE1 has changed! Update dependent command (Moves,
Feature THEO, ACTL, and TARG values)?

Choose 'Yes' to convert the dependent commands to the new alignment coordinate
system.

Choose 'No' to leave the dependent commands unchanged.

Yes/No message asking if PC-DMIS should update dependent commands

You can choose to convert the dependent commands to the new alignment coordinate
system or to leave the dependent commands unchanged.

The text in the message indicates what types of commands and command values the
software updates for each alignment change.

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Updating Dependent Commands When the Alignment Changes

Different commands and command values may change depending on the transform
change. This table lists the commands and command values that are updated after a
transform change:

Transform Change
Machine-to-Part Cad-to-Part Both
• Move
commands
• Feature
Commands and • Feature
• Move command
command values command
that may update commands THEO
THEO
after a changed • Feature • Feature
• Feature
transform: command command
command
ACTL ACTL
TARG
• Feature
command
TARG

In the following two general scenarios, you need to decide how to update the
commands in the measurement routine in response to an alignment change:

1. Loading a measurement routine that recalls an external alignment file. See

"Updating Commands When Loading a Measurement Routine " below. below.
2. Adding a new alignment or modifying or deleting an existing alignment while in
Learn mode. See "Updating Commands While in Learn Mode" below.

Updating Commands When Loading a Measurement Routine

A measurement routine that includes RECALL/ALIGNMENT, EXTERNAL commands

attempts to re-load the referenced external alignment files each time the measurement
routine opens.

The correct answer to the question "Update dependent commands?" depends on why
the external alignment file has changed. Consider these reasons:

• The Alignment file changed because you moved the part on the CMM - In
this case, the theoretical and actual values of the commands dependent on that
alignment need to remain fixed, relative to the part (see the figure below). The
Machine-to-Part transform is modified. It’s possible that the Cad-to-Part

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transform is also modified, but that is not very common. Choose No at the
Yes/No message so the values of the dependent commands do not change. The
position and orientation of the part can then change while retaining the previous
dimensional information, similar to equating an alignment. This is the most
common scenario.

Part Moved on CMM

• The Alignment file changed because you made small adjustments to the
alignment to see how it affects the measured results, without actually re-
measuring the part - In this case, the values of the dependent commands must
be updated to the new alignment coordinate system. The Machine-to-Part
transform is modified, but the Cad-to-Part transform has not changed.

This usually requires the SAVE/ALIGNMENT command be configured to

only include the Machine-to-Part transform, not both transforms.

Choose Yes at the Yes/No message.

• The Alignment file changed because the you moved the alignment origin to
a new location on the part, but you did not move the part itself - For
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Updating Dependent Commands When the Alignment Changes

example, you changed the level, rotate, and/or locate features to different
features. In this case, theoretical and actual values of the commands dependent
on that alignment must be updated to the new alignment coordinate system. The
Cad-to-Part transform has been modified, but the Machine-to-Part transform has
not changed.

This requires the SAVE/ALIGNMENT command to be configured to

include both transforms.

Choose Yes at the Yes/No message so that the measured data does not shift
away from the CAD geometry. This is not a common scenario.

When loading a measurement routine that recalls an external alignment, if the external
alignment file transforms have been modified since the measurement routine was last
saved, by default, PC-DMIS does not display the dialog box, asking to update the
dependent commands. Instead, it automatically answers No to that question. You can
control this behavior with the UpdateExtAlignmentDepCommandsDuringFileOpen
registry entry. For information on how to modify values for registry entries, see
"Modifying Registry Entries".

Updating Commands While in Learn Mode

When you edit a measurement routine in Learn mode, if changes are made that modify
or delete an existing alignment command or create a new one, PC-DMIS asks if you
want to update the commands dependent on that alignment.

The correct answer to the question "Update dependent commands?" depends on why
the alignment definition has changed. Consider these reasons:

• The alignment definition changed because you moved the alignment

command origin to a new location on the part - For example, you changed
the level, rotate, and/or locate features to different features. In this case, the
theoretical and actual values of the commands dependent on that alignment
command need to be updated to the new alignment coordinate system (see the
figure below). Both transforms have been modified.

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 Creating and Using Alignments

Alignment moved on part

Choose Yes at the Yes/No message so that the measured data does not shift
away from the CAD geometry. This is a common scenario.

• The alignment is from a command that recalls an external alignment

(RECALL/ALIGNMENT, EXTERNAL), and you changed the file reference to
a different external alignment file that represents the part at a different
location on the CMM - In this case, the theoretical and actual values of the
commands dependent on the alignment remain fixed relative to the part. The
Machine-to-Part transform has been modified, but the Cad-to-Part transform
needs to remain the same.

Choose No at the Yes/No message so that the values of the dependent

commands are not changed. This is a less-common scenario. It allows the
position and orientation of the part to change while retaining the previous
dimensional information, similar to equating an alignment.

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