SolidWorks is generating random mate errors. This intermittently happens when loading an assembly or switching between configurations inside of an assembly. The only two ways that I've found to clear the false mate error is to either delete the mate and re-mate or restart SW. The mate generating the error is unchanged for all configurations but somehow SW gets confused and either looses the face/edge or automatically re-associates one of the features to a random feature on the other side of the part.
The first assembly to have this issue had only 136 parts, 207 mates, and 8 configurations driven by a table. But I have received this mate error on a small assembly, less than 10 parts, on a coincident mate between two flat faces! I have come to expect SolidWorks to have issues with angle mates but not coincident flat face mates.
I'm running 64-bit SW on Windows 7, with all data saved on a server and have never had any issue like this prior to 2010 SP2.1.
I'm just wondering if I'm the only one who has this issue and I need to do a fresh reinstall of SolidWorks or if anyone else has this problem.
I spoke to our VAR. This is a known issue under SPR 549553 and has the impact level of 'Critical'. He is checking to see if this has been an issue for all 2010 releases, or if it is possible to roll back to a previous SP release. If I get more information, I will pass it along. Internally, a "reload from DISK" has been successful in clearing the problem, but it returns with each fresh open. On one assembly that I can open repeatedly with an error, then reload from disk and clear it, I can open the assembly lightweight and not get any errors.