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Start/End Distance Validation Failed

Platform: Process Simulate

Listed weld operations use Start/End Distance (SD/ED) values outside the gun-axis actuator limits for that robot and gun. Resolver blocks export until those values are brought back inside the printed range (same SD/ED concepts as the schedule warning, but evaluated on the active weld data shown in the dialog).

Dialog shown in Resolver​

Start/End Distance Validation Failed 

The following weld operations have SD/ED values outside actuator limits:

  • Operation: {operationName}, Robot: {robotName}, Gun: {gunName}

  SD={sdValue}, ED={edValue} outside limits [{minLimit}, {maxLimit}]

...Press OK to dismiss after noting the failing SD/ED values.

What you can do in this dialog​

  • Can you continue export? No
  • Buttons in the popup: OK
  • What happens next: OK dismisses the dialog; export stays blocked until SD/ED values are valid.
  • Next step: How to fix it

Impact if you continue​

There is no export to continue with: Resolver blocks until every row in the dialog is fixed. SD/ED left outside the gun-axis limits would imply gun-axis poses outside the permitted working range, so Resolver does not build motion from that data.

How to fix it​

  1. Click OK in the error dialog to dismiss after noting the failing SD/ED values, then fix the setup below.
  2. Select the affected robot in the station.
  3. Open Robot Setup.
  4. In the setup dialog, open Robot And Guns Setup.
  5. Select the affected Gun tab.
  6. Open Distance schedules.
  7. Select the schedule index from the dialog.
  8. Adjust distance parameters (for example Dst gun) so values stay within limits.
  9. Click Store to save schedule changes.
  10. Save the station and run Resolver export/import again.
  11. If the error still appears, repeat for the next robot/gun pair from the dialog.

Distance schedule edit flow in Robot Setup