did you resolve this?
Can you elaborate on the part regarding:
"The irVision reference frame and the conveyor TrakFrame are aligned with each other to within 1deg,"?
Is this specified in the manual?
I have found that most errors come from a false height input in the irvision/tracking frame settings relative to the part. Make sure that all your heights are correct. Make sure you are correctly calibrating camera with the correct standoff/focal distance.
Make sure your center of rotation in IRvision is correct.
I would love to hear what the resolution was if you found it!