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Aligner Troubleshooting Guide

Aligner Troubleshooting Guide

This guide provides quick solutions for template alignment issues on the OV80i camera system.

Quick Diagnosis​

Is the aligner supposed to be running?​

Check Skip Aligner setting:

  • Go to Template Image and Alignment
  • Ensure Skip Aligner is NOT checked
  • If checked, uncheck it and test alignment

Basic Alignment Test​

  1. Switch to Live Preview Mode
  2. Place a part in the camera view
  3. Look for moving ROI boxes - they should follow the part
  4. Check confidence value - should be >60%

Common Issues & Solutions​

Issue: Aligner Not Working At All​

Symptoms: ROIs don't move, confidence shows 0%

Quick Fixes:

  1. Check Template Regions exist - at least one required
  2. Look for red highlights in Template Regions
  3. Increase Sensitivity to 80-90%
  4. Re-capture Template Image if corrupted

Issue: Inconsistent Alignment​

Symptoms: Works sometimes, fails other times

Solutions:

ProblemFix
Template Regions on variable featuresMove regions to stable edges/corners
Poor lightingImprove lighting consistency
Dirty partsClean parts or choose different features
Template image outdatedRe-capture template with current parts

Issue: False Alignment (Wrong Position)​

Symptoms: High confidence but wrong alignment

Solutions:

  1. Increase Confidence Threshold to 85-95%
  2. Add more Template Regions for uniqueness
  3. Choose more distinctive features

Issue: Red Highlights (No Edges Detected)​

Symptoms: Red highlights in Template Regions

Quick Fixes:

  1. Increase Sensitivity slider
  2. Improve lighting on parts
  3. Choose areas with sharper edges
  4. Check camera focus

Issue: Slow Alignment​

Symptoms: Long delays during alignment

Optimizations:

  • Reduce Template Regions to 2-3 most effective
  • Reduce Rotation Range to actual needs
  • Lower Sensitivity to minimum effective level

Template Region Best Practices​

Good Template Region Placement​

✅ Place regions on:

  • Sharp corners and edges
  • Unique geometric features
  • High contrast areas
  • Stable part features

❌ Avoid regions on:

  • Textured surfaces
  • Reflective areas
  • Parts that might be missing
  • Small details that get dirty

Edge Detection Check​

  • 🟢 Green highlights = Good edges detected
  • 🔴 Red highlights = Need more sensitivity or better features

Parameter Quick Reference​

ParameterRecommendedPurpose
Confidence Threshold0.7-0.9Balance accuracy vs flexibility
SensitivityLowest that gives green highlightsAvoid noise while detecting edges
Rotation RangeMatch actual part variationMinimize to improve speed

Emergency Bypass​

If alignment can't be fixed immediately:

  1. Enable Skip Aligner in Template & Alignment settings
  2. Position parts manually and consistently
  3. Verify inspection still works without alignment
  4. Fix alignment during next maintenance window

Troubleshooting Decision Tree​

Alignment Problem?
├── Skip Aligner enabled? → Disable it
├── No Template Regions? → Add regions on stable features
├── Red highlights? → Increase sensitivity
├── Inconsistent results? → Check Template Region placement
├── False positives? → Increase confidence threshold
└── Too slow? → Reduce regions/rotation range

🔗 See Also​