Nozzle check failing

[Jason]

Starting a simple test job in RVplace goes and picks up
the rear right hand nozzle (#5?). I know I must have the right
nozzle in the tool holder as this is the largest nozzle and
won't fit into any other slot.

The head takes it to the fixed camera where I see a clean
vector drawn circle and then I get an error saying that
the nozzle might be worn, or the camera might be
dirty etc.

Looking at the calibrate menu the picture looks clean.

1) What aperture/iris setting are other people using on
their lens? Wide open, very closed or just in the middle?
This will affect depth of field as well as brightness so is
obviously important.
2) How high do people have the lens focussed before
calibration?
3) I seem to have (according to the drawing files)
nozzles 3,4 and 5.  #5 Appears to have the camera
tool insert (aluminium) in it. Should I remove this when
placing? Could that be the source of the error?

thanks.

[Mike]

It seems to do this check apparently randomly, and AFAIUI it does it on some jobs but not others. I've not seen it happen for quite a while on mine, but I think on some jobs it did it at the start of every run. 
Not sure exactly what it's checking for -  can only assume camera scaling and aspect ratio.
Camera depth of field should be pretty small - parts are always held at a specific height, plus the component height in the CDF.

[Jason]

It appears to be related to the "Use camera always/never" option in rvplace.
I'm guessing this option is saved per job file.
I'm skipping the check as I can't get it to complete.

Going back to the aperture, assuming we all have the same
camera and the lighting is similarly bright, what threshold
value are people using for the static camera?
This way I can adjust my iris to match.

Any takers on whether the aluminium insert should be
removed after camera calibration?

Anyway, I've now got to the point where a job starts
running, I just don't have a full set of tools so I'm a bit
stuck until I can get some more tools. I did PM RvSystems
but no answer yet. I might have to turn some up on the
lathe.

[Mike]

Any takers on whether the aluminium insert should be
removed after camera calibration?

Mine has what looks like a nylon insert - can't see why you would remove it - the hole isn't small enough to affect the flow of suck.

Going back to the aperture, assuming we all have the same
camera and the lighting is similarly bright, what threshold
value are people using for the static camera?
This way I can adjust my iris to match.

Probably not very meaningful to set to a 'known' setting as it will depend on things like how old the LEDs are - apparently they change over time.
For the iris I'd suggest just open enough to get a good image in greyscale mode - if too open, it will be more sensitive to variations in ambient light.

[Jason]

I get corruptions in the "real mode" diagram at 160 and 240
so I've set the threshold to 200. . . Still doesn't work.
I assume the focus should be done with tool #5 attached.

I'm guessing if this doesn't pass then I'm going experience
errors in compontent rotation checks.

Nice to see your tool #5 also has butchered edges!

[SteveW]

"I'm guessing if this doesn't pass then I'm going experience
errors in component rotation checks."

Nope. Or, at least, I don't think so. That  nozzle rotation check doesn't check to see that rotation happens correctly, as it's spinning a centered circle in a circle. It can check that the arm and the camera are lined up right, and that the tool picker-upper isn't bent, but I think that rotation is unlikely to be what it's worried about.

After a recent machine move, my main machine has started failing this test, and I've been too busy to worry. No sign of any rotation problems - and I've got no idea why it fails the test, the outline picture looks much as it did when the test passed. The fact that it was always optional makes me feel quite relaxed about poking the 'just get on with it anyway' button...