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Merge v9.2 into main#617

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merge-v9.2-main-27104
May 8, 2026
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Merge v9.2 into main#617
JWhitleyWork merged 3 commits into
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merge-v9.2-main-27104

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griswaldbrooks and others added 2 commits May 7, 2026 10:01
…ndling cartesian fixes

Addresses two distinct bugs surfaced in the factory_sim package by
PickNikRobotics/moveit_pro#18180.

1. Bracket spawn-position errors at sim reset.
   <replicate count=3> in description/scene.xml interacts badly with
   MuJoCo 3.2.7's keyframe parser, silently corrupting the first
   replica's qpos slot -- bracket-0-0 lands under the pedestal on every
   reset. MuJoCo 3.3.5 hard-errors on the same input
   ("Keyframe 'default' has invalid qpos size, got 48, should be 13").
   Fix replaces <replicate> with three explicit <include> blocks of
   per-bracket geometry files.

2. Tool-handling cartesian rejections at the holder.
   Two cartesian motions in the suction-gripper subtrees deterministi-
   cally land link_6 at the suction_gripper world object (depth = 0):
   - Pick Up Tool from Holder's +0.10m approach push.
   - Place Tool in Tool Holder's 0.35m post-detach Retract.
   The pair link_6 <-> suction_gripper has no ACM entry (default
   NEVER), so the planner rejects both segments. Previously masked by
   <replicate>'s non-deterministic IK ordering. Fix opts each segment
   out of environment-collision checks; the cartesian paths are purely
   vertical along tool0 Z, so wrist swings into other env are
   precluded by the path itself.

Plus three small simulator-side fixes folded in (keyframe qpos row
order corrected to match MuJoCo's body compile order; default joint
path tolerance bumped to 0.65 to clear joint-6 deviation against the
0.6 limit; MuJoCo arena bumped from 15M to 64M to prevent contact-
constraint overflow during the place phase, which had been segfaulting
ros2_control_node via the viewer's next sync).

Edits:

- description/scene.xml -- keyframe qpos rows reordered; <replicate>
  block replaced with three explicit <include>s; arena bumped to 64M.
- description/bracket_collision_geometry_{0,1,2}.xml -- new per-bracket
  geometry files referenced by the includes.
- config/control/picknik_fanuc.ros2_control.yaml -- default_path_-
  tolerance bumped to 0.65.
- objectives/pick_up_tool_from_holder.xml -- ignore_environment_-
  collisions="true" on the +0.10m SetupMTCMoveAlongFrameAxis;
  SetupMTCIgnoreCollisionsBetweenObjects(link_5;link_6;suction_-
  gripper) added matching the sibling subtree pattern.
- objectives/retract.xml -- parameterized ignore_environment_-
  collisions as a new input port with default "false" so existing call
  sites keep their hardcoded behavior; threaded through to the
  underlying SetupMTCMoveAlongFrameAxis.
- objectives/place_tool_in_tool_holder.xml -- passes ignore_-
  environment_collisions="true" at its 0.35m Retract call site so the
  post-detach retreat clears the same depth = 0 contact.

Refs PickNikRobotics/moveit_pro#18180

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
…tory-sim-issues

Fix: 18180 factory_sim Pick and Place sim setup and tool handling
@JWhitleyWork JWhitleyWork force-pushed the merge-v9.2-main-27104 branch from a4085f2 to eab4a90 Compare May 8, 2026 19:15
@JWhitleyWork JWhitleyWork self-assigned this May 8, 2026
@JWhitleyWork JWhitleyWork marked this pull request as ready for review May 8, 2026 19:17
@JWhitleyWork JWhitleyWork added this to the 9.3.0 milestone May 8, 2026
@JWhitleyWork JWhitleyWork merged commit e6efe00 into main May 8, 2026
3 of 4 checks passed
@JWhitleyWork JWhitleyWork deleted the merge-v9.2-main-27104 branch May 8, 2026 19:40
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2 participants