#pointsWithinEvalRange Error Message

[[Ia...]]

I am new to curve (again) after being away from it for a few years, and I have never seen this message. This is the result of recalling sections of a curve to another curve. It happens to random curves from part to part. It really messes with Calypso (2019) and the operator had to force close calypso because the error kept appearing after every interation.

My working theory is that since the curve is filtered with outlier removal, it is having a hard time recalling specific points that may be the ones being filtered. I haven't been able to test this, and won't be able to until tomorrow afternoon. I'd just like to have a gameplan ready for when I have the chance to correct this.

Should I unfilter and remove outlier elimination for all of the curves and just filter them in the characteristics? Will that fix this error message from ever happening? Or is it something else entirely?
Thanks for the help.

[[Je...]]

Try increasing the "max search distance" in the evaluation setttings of the curve.

[[Ia...]]

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Thanks for your response Jeffrey. I upped the search distance by about 4x and removed filters and outliers. The error message went away, but now my report is giving "Error with References" and not displaying any actuals for the same curves.

Edit: When I open the curve features that are giving me problems, the error message pops up again.

[[Ma...]]

How do you recall points? Using box?

[[Je...]]

Typically when this error occurs it is when a curve was created from nominals with default or decreased "Max Search Distance" and the curve was then copied to a new program or location with different nominal sizes/locations/orientation. Many programmers will assume that the curve will still work as the "form" of the curve is the same (IE family of parts but this part is larger/smaller than part used to create curve). However, if the location of the actual points are not within the search distance value of nominal point location, the Curve feature will not evaluate them.

To adjust the Max Search Distance for your feature that you are unable to open, you can try this as a workaround to preserve it;
1 - Create a new curve feature (be it a 2d or 3d Curve, same as the feature you are trying to correct).
2 - Use the "transfer format" option (paint brush) and apply the Evaluation settings of the original Curve feature to the new Curve feature.
3 - Open the new feature and adjust the Max Search Distance to a larger value. The value isn't going to be used forever after this so you can try something like 100mm initially. If you were unable to open the new Curve feature after transfering the Evaluation format, start over with Step 1 again but skip Step 2 this time. Step 2 just preserved any settings you had for Evaluation originally.
4- Now use the "transfer format" option (paint brush) and apply the Evaluation settings of the new Curve feature back to the original Curve feature.
Open the original curve to see if the error has gone. I don't know the specific scenario so this may not be the solution but this is usually how to resolve the issue when the above statement is the cause. You will then need to adjust your nominals or alignment to reflect proper nominals. Leaving the Max Search Distance wide open as this may bring other issues into play.

In the future;

There are a few ways to mitigate problems with this situation in the future. The best is a local feature alignment for the feature so that nominals for scanning originate from localized features (as in points taken right on geometry included curve feature). This way the size of the part or general location of curve relative to base alignment is not a factor. Use recall feature points with the proper alignment to get the points in to the required DRF in a subsequent Curve feature. Another method, less desireable, is to open the "Max Search Distance" up much wider. This field is not intuitive to its function as it would imply that it is applying to the tactile/optical scanning of the workpiece. However, this field is located in the evaluation tab, the "Max Search Distance" is the distance from nominal location of each point that Calypso will evaluate measured data. The reason to keep this value small is it significantly affects the calculation time of the curve feature. My programming rule of thumb is total possible stackup of the feature tolerances relative to the feature aligment X 5. So if the maximum allowed profile deviation for that curve feature is 0.100 and the feature alignment is the same as the print requirement then my search distance would be set to 0.100 x 5. So a Max Search Distance of 0.500mm. If the feature aligment is not to print alignment and the feature alignment could shift 0.050 relative to base alignment then I will add that to the calculation as well.

If the curve has a lot of data associated and the Max Search Distance is set too large then the calculation time could be excessive. To give an example, I have reviewed Curve heavy programs that took 20+ minutes to calculate after measurement is completed. Just adjusting the Max Search Distance to proper values on 2d Curves and 3d Curves took that time down to 2-3 minutes.