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Leica TCP 1205 gives wrong stake out distances when in robotic mode

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(@driftingsand)
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What follows is the single most bizarre experience I've ever had while land surveying.?ÿ
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I have a Leica 1205 TCP robot from roughly 2003 in the field. I went to a construction site and set up over a point. I then backsighted another point, with a good distance check. Something like 0.03' horizontal and 0.01' vertical if I can recall correctly. My point is, I know for sure that I was on the correct points, no mistakes there.
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I then do a power search and get a lock onto my 360 prism. I move the rod slightly to the left and right, while watching the horizontal angle right on the data collector. The angle correctly moves as I gently move the rod, so this is a confirmation the robot is locked onto the prism and not some other random refelctive surface.
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I am using an Allegro data collector which runs a SurvCE software from 2007. This is carlson's data collector software, if I understand correctly.
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Now I begin staking out a house corner.
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The display on the screen then tells me to go 120 feet back and 60 feet left. Except, I personally know that I am on directly on top of the stake out point already. How do I know this? I've already staked out this data with an older, non-robotic leica total station during an earlier visit. I'm just back again to do some grading.
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In complete disbelief, I then attempt to stakeout one of the septic system points. In reality, it's about 150 feet back from where I am. The robot then tells me to go back 300 feet and left 100 feet or so. It's roughly off 100-200 feet for each of the points. Both the distance and angle seem to be wrong.
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I have a copy of the plan that I printed that morning from Civil3d 2009. Using a ruler, I scale off the distances to the stake out points from an existing neighboring house corner. They make perfect sense with what the older, non-robotic leica total station says they should be.
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I return to the office and verify all coordinates in the Allegro collector are accurate. Sure enough, they are all completely fine. I didn't mix up northing and eastings. I can confirm that the coordinates listed in the points list on civil3d 2009 are exactly the same thing in the collector's point list. I mouse over the points of interest and look at the coordinates being displayed in the lower portion of the screen. They are fine, and match exactly with the points list.
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I use this robot all the time as a manual total station with the robotics turned off doing large boundary surveys. We just had a 112 acre survey close over 41 setups for 0.21' or a quality of 1:61,000 which is pretty good. This should serve as evidence the total station itself is capable of turning good angles and shooting good distances, at least in manual mode. This was done with the same data collector I am using with the robot to stake out during my example.
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So therefore, how in the world is it possible the robot is giving me such bad distances and stakeout directions? I know this is an old machine. This issue only seems to ever happen in robotic mode while locked onto a prism. When in manual mode, the total station works fine.
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I did some searching around and found a thread by someone else who said they had issues with the same type of robot. They tracked down the problem to something called the ATR Camera which had become faulty somehow. Is this the component that causes the robot to follow the prism while it moves around? But, wouldn't that only affect the robot's ability to lock onto a target? How would that hardware part also affect distances and angles?
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Would anyone kindly offer any insight into what they think the issue is with this robot?
 
Posted : 19/03/2020 3:23 pm
(@ekillo)
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I have about the same setup as you,except my robot is a 2003 or 2004 1203.

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One question is did you try to stake out your backsight point as a stakeout point after you took your backsight?

is it possible that you have a control file that is different from your job file?

I would not think that it is a robot issue, it is just a data terminal passing its readings to the data collector, somehow the collector maybe getting feet and metters crossed up.

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Ed

 
Posted : 19/03/2020 4:05 pm
(@paul-in-pa)
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I would surmise that your data collector to robotic TCP is thinking it uses a different mode, scale factor or other hardware specific alternate. Degrees vs other , metric vs feet. It appears you set up manually and checked a second point and know they are in your system, now go back and stake out that second point in robotic mode and write down exactly what it tells you to do, versus what you know it should tell you to do. Purposely resatke out to points exactly 1' left, right, near and far and also compare. Once you have done that for several other points it will lead you to a conclusion. Without actual precise readings we are at a total loss here.

ekillo has a point.?ÿ It is possible to setup in one file, stake out a second file and record those shots in a third file. I did that once unintendedly and it drove me crazy for a while. So once in robotic mode make sure your instrument and backsight are on the points in question from the file in question. That check you can actually do now in the office, get out your data collector, set it to manual mode and write down your stakeout directions and distance, then switch it to robotic mode and do it again.

Paul in PA

 
Posted : 19/03/2020 4:05 pm
(@jacob-wall)
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Is it possible that the setup / orientation was done in Face II? I know some software used to have problems under those circumstances. Otherwise I would be interested in seeing the SurvCE raw file if you could record those observations.

 
Posted : 19/03/2020 4:07 pm
(@jmh4825)
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Make sure your scope was not inverted. I have same robot and use surv ce. Take a look at your raw data, are zenith angles way off? I have accidentally done this a few times and got bogus results.

 
Posted : 19/03/2020 5:22 pm
(@kevinfoshee)
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Sounds like you were set-up on the point you told the data collector you were backsighting and backsighting the point you told the data collector you were set-up on? I've have that happen before. It usually looks just like you describe.

 
Posted : 20/03/2020 8:22 am
(@micheal-daubyn-2-2-2)
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KevinFoshee's answer above is probably on the money. Me likey-likey.

Although, something you said grabbed my attention:

"They tracked down the problem to something called the ATR Camera which had become faulty somehow. Is this the component that causes the robot to follow the prism while it moves around?"

Yes it is.

"But, wouldn't that only affect the robot's ability to lock onto a target?"

Perhaps not.

"How would that hardware part also affect distances and angles?"

Good question. It shouldn't. Unless it being faulty has had a flow-on effect further down the road.

After stripping a destroyed instrument for fun recently (a non-plus model), I can tell you that the connections between the hardware components are as follows:

The mainboard sends all of the info through the head into the EDM board. The EDM board then runs the ATR board, which in turn runs the camera as well as the Powersearch board. Essentially, they are all physically connected in sequence. Electrically, I didn't bother checking to see if the ATR and Powersearch boards are only passively running through the EDM board or whether the EDM board does some of the thinking for the other two boards and the camera.

Having said that, all of the info for all of those "thinking" components runs through a ribbon cable containing only 8 separate wires. They are all sharing physical resources and sending differently coded signals in machine code back to the mainboard; which the mainboard then interprets. That interpretation could be your problem.

In other words, the ATR camera (or anything else upstairs) being faulty could absolutely cause that problem, because the faulty component could corrupt the message somehow (unlikely though. Things usually either work or they don't when code is involved.) The thing I would be focussing on is why this problem only presents itself when the RCS is turned on. That's odd. It sounds like a firmware issue. That would point the finger back at the mainboard. Nothing upstairs should care if the RCS is on or not.

If you look at the photo I attached (it's from an 1100, but you'll see what I mean) you'll see the 8 strand ribbon cable that I'm talking about. Essentially, I wonder what would happen if you disrupt the chain of info somehow.....like with a faulty camera.?ÿ That's why the ATR camera theory makes some sense- except that it is the ATR camera that locks onto the prism and tracks it- not the Powersearch module. PS only finds the prism roughly then hands over the duties to the ATR. And you said that you are getting a lock, so.......

Do the ATR and Powersearch behave themselves when the instrument is not in RCS mode? You mention it being ok in "manual mode". Does "manual mode" mean fully manual? Do you use the ATR and Powersearch in non-RCS mode or are you turning and sighting targets without the ATR at all?

Again, I am NOT a technician.

Mick

2

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Posted : 20/03/2020 5:18 pm
(@driftingsand)
Posts: 7
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Topic starter
 
WOW!!! Nice guys, thank you! I am extremely grateful for all the very knowledgeable comments from everyone! Especially Micheal D'Aubyn, oh my god.
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I had not tried to stake out my backsight point as a verification after experiencing the field issues with the wrong stake out distances. This is a good suggestion! I was in such a frustrated mood when this happened, I just assumed that something went wrong with the import of the coordinates from the text file export option from civil3d. I didn't stop to think about more field tests that could have helped. If this happens again, I will definitely do that.
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Speaking in terms of control files, I just use a single text dump for the entire job. I know some companies use separate control files in large jobs, we personally don't. Therefore I believe I can answer that the control file is the same as our job file.
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You know, it's interesting you mention the collector possibly getting feet and meters mixed up. Years ago I had a boss that was using SurvCE on an older Sokkia manual total station. Very rarely, I think this happened only once to us personally, the data collector would misunderstand the distances being shot as a factor of 3 or so. So if you shot a distance of 100 feet, the data collector would think it was 33 feet or something roughly like that.
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My boss at the time, he actually called Carlson and asked what was going on, if they knew anything. And Carlson actually admitted that yes, there was a rare conflict with that total station and that particular version of the data collector software. So there is such a thing as weird software problems going on with these things.
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I will check for any possible scale factor problems, that is another good suggestion. My old boss used to suggest that all the time, "Check the scale factor!" as a possible issue. In fact he said it so many times, I began to wonder why they even offered scale factor as a configurable option on the collectors, since it was always the first thing to look at if there was a problem. I've never had to touch it from 1.0000000000000
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I did the inverse check in the data collector, it matches exactly with what was in civil3d. Good suggestion. I remember doing inverses in the field to verify, but had to wait to get back to the office to see what the inverses were in the computer software.
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I can confirm the setup was done in face 1. I always set me orientation in face 1, and when face 1 is active, the vertical control is on the upper left side of the instrument which I always use with my left hand. I can remember precisely doing this, so it was definitely face 1. Thank you for the suggestion though.
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Scope Inverted, Hmmmmmm. I'll take a look at my raw data for anything strange. I told my boss about this, the plan now is just to see if it happens again and if so, then action will be taken. They want to reproduce the issue before spending any money. That's just their stance on it.
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I thought perhaps I had mistakenly made the backsite and foresight reversed, but then again, I got such a good vertical check that I figured this would not be the case. Usually that is the only defense against accidentally mixing up the foresight and backsight, is that the vertical check is bad. But it could be just pure luck that the 2 sites are set up in such a way that it would be the same either way with exact instrument heights? Seems super rare that this would be the case.
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I did a direct inverse vertically between the 2 points I was set up on, and the distance was
Vertical: 0.9081000
so they were not on nearly the same elevation or anything, so a bad vertical check in shot should catch a reversed occupy and backsight point.
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Micheal D'Aubyn, huge thanks for your response, me very much likey-likey!!! I am greatly impressed with your technical knowledge, even when you said you don't consider yourself a repair technician! I love your suggestion of updating the firmware on the total station. I know it's super old, though. And I have heard of Leica required something called a CCP Customer Care Package to be active before they let you update the firmware, which is pretty lame. Basically you have to pay them to fix their own mistakes.
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Cool photo there, thank you. I saved it to my desktop, I'm gonna show my boss later. I think it will help explain the amount of research we have all put into this very odd problem.
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I've certainly got my work cut out for me! First thing I'm going to do is update the firmware, then I'm going to check all the scale settings on the data collector, and so and so forth.
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Again, wonderful thanks for all the incredibly insightful replies I've gotten from your community!
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Posted : 23/03/2020 3:50 am
(@ekillo)
Posts: 559
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@driftingsand

I had to get a CCP which cost me $450 to update the firmware on my 1203 to the latest version.  My instrument used to take several seconds to turn off, after the update it turns off much faster, the other advantage to updating is it will allow you to use a RH16 handle that is bluetooth, so you could update the collector later if you decided to go that route.

Ed

 

 
Posted : 23/03/2020 4:27 am
(@john-putnam)
Posts: 2150
Customer
 

@driftingsand

Vertical check would be the same if you were set up on the supposed backside.  At least the variance would be the same.

 

 
Posted : 23/03/2020 6:32 am
(@norman-oklahoma)
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I make a habit of checking into a 3rd control point, that is one other than the backsight, before proceeding with staking. I wrote about this in a thread about resectioning just a couple weeks ago.?ÿ

As I said then, "the ways of the blunder are many, and varied". I've been doing this stuff for over 30 years now, and I still find new ways to screw up. Keep in mind that in order for you to match up to previously staked points, that previous staking had to have been right as well.?ÿ ?ÿ

https://surveyorconnect.com/community/surveying-geomatics/quick-resection-question/#post-519137

 
Posted : 23/03/2020 6:52 am
(@dougie)
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Posted by: @john-putnam

Vertical check would be the same

Only if the measure ups were the same...

 
Posted : 23/03/2020 7:05 am
(@john-putnam)
Posts: 2150
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@dougie

Okay, I typed before coffee.

 

 
Posted : 23/03/2020 8:41 am
(@zammo)
Posts: 104
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Being a 1200 series have you tried using the on-board software to test? This could be an independent check to eliminate the data controller being the issue. I thought maybe the metric vs imperial settings in C3D being the cause, but if the control is in the same file then that eliminates that being the cause.

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Also, as dumb as this sounds, I've had an issue in the past with Trimble Access loosing custom prism constant values when switching prisms, on one occasion I couldn't figure out why my readings were over 300mm out until I realised I forgot to enter a decimal point. That was definately a face in hand moment ?ÿ 😆 ?ÿ?ÿ

 
Posted : 24/03/2020 3:56 am
 zak
(@zak)
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I think that is because the machine is old , I got the same problem with trimble and topcon

its laser not work good

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Posted : 27/03/2020 9:56 am
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