Can't use CAD Evaluation Graphics on FreeForm characteristics

[[Ri...]]

This is a first, I have one program with about 48 FreeForm features.
I went as far as to recreate the FreeForm features and I still can't use CAD Evaluation for graphics.
I have a screenshot and a text file for the error report.
When the "Result" tab and the "Display" option is checked, almost everything on the Evaluation dialog box that interacts directly with CAD causes an error.
Simply selecting a profile characteristic that has FreeForm feature causes the error when the "Result" tab and "Display" option is checked.
I can close the Evaluation dialog box while the "Display" option is checked and still get the error when selecting any FreeForm profile characteristic.

Now it gets weird.
I can create a new FreeForm feature associate it to a Profile and all the interactions with the Evaluation screens work fine.
Once I run the FreeForm feature to calculate a result via the Profile, it starts with the errors.

I have other programs using FreeForm that do not have this issue.

Any assistance is appreciated.

Edit:
I am using a typical Profile for some FreeForms and a Bilateral with one result for others. Both have the same error created.

New Text Document.txtCapture1.PNG

[[Ma...]]

Are you recalling points into FF or you have defined path?
I would check if a path don't go by bad area ( small faces in between big ones - i see some yellow points on screenshot ).
If selecting used faces helps, then it's definitely from model.

[[Ri...]]

These are all sections from a model, no recalled data.
Many of the small sections have pitch and roll, they are not surfaces that can have geometry extracted.
I will see if I can get a new model, perhaps a different format.

The yellow points, thanks for detecting that. I can clean those out.

[[Je...]]

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Hey Rick. It sounds like you've zeroed in on the problem. The text file you provided agrees with that hypothesis. The normal vectors are not defined fully, which may be due to those extra features indicated by the yellow lines, or something similar.

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I think Calypso could do a much better job of making its error messages easy to understand and helpful:
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[[Ri...]]

Looking into the Sections, there are no "dots". This is nothing more than looking at the CAD model from -Y axis. Some of the section lines/curves are blocked by lines/curves from the model making it appear to have "dots".

[[Ri...]]

Looking into the Sections, there are no "dots". This is nothing more than looking at the CAD model from -Y axis. Some of the section lines/curves are blocked by lines/curves from the model making it appear to have "dots".
All of the yellow lines are used and appear to be cleanly defined in the CAD geometry.

If the vectors are "undersize" how are these Profiles calculating a result and only affecting the "Evaluation" dialog box?
Now I have to wonder if the 16 plus parts I have ran has invalid data.

[[Je...]]

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Thanks, Rick.

Just a troubleshooting step, and probably not the issue, but have you reviewed whether the morphological filter is enabled and if so which settings are applied?

Also, are all of the surfaces that you intend to link to each free form feature showing listed and showing visual feedback that they are properly connected?


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[[Ri...]]

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1. It is my understanding that Morphological is for vision systems. If anyone knows different, please explain.

2. Yes to this entire question.

I generally have used default Filter settings as they work quite well.
"For the the Gaussian and Chebyshev best fits, the deviations are calculated between actual points and the facets of the approximated CAD model. The maximum accuracy then depends on the selection made under Display / Image Quality in the CAD Settings window."

My "Display Quality" (In Bold) is "High <.010" and in some cases, depending on model size/complexity "Very high <.005".
I have found there can be ASIC issues on complex models set at "Very high >.005" (Most likely from my Graphics card).

[[Je...]]

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Thanks, Rick.

I agree that morphological filtering is more common on optical inspection. Mostly what I meant was to check that it wasn't turned on.

Have you gained any traction with figuring out this problem yet? Sounds frustrating.

[[Ri...]]

The CAD Evaluation issue is limited to FreeForm only in this program.
I am going to create a new program and copy/paste from old to new, maybe that will get rid of the error.

[[Ri...]]

Copy/Paste from old program to a new program did not resolve the issue.
However, I now have a new CAD model and this appears to have resolved the issue.

For some reason, using a SolidWorks model and converting to Step or Iges created a problem.
Converting the SolidWorks to a SAT seemed to have worked out.