how to debug MoveIt 2 OMPL planner FAILED to find motion plan after collision object add

By Sai Kiran Pandrala · Last verified: 2026-06-01 · Source: OEM service bulletins and changelogs, controls-community forums (r/PLC, r/Robotics, r/CNC, r/Fanuc, r/KUKA, r/Cognex, r/labview), in-controller diagnostic help, OEM service manuals

how to debug MoveIt 2 OMPL planner FAILED to find motion plan after collision object add on ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 comes up often enough on the shop floor and in the OEM service bulletins that there is a stable recovery pattern. My first step on any ros fault is to read the alarm history before touching the reset button - last week the cell controller hit this exact alarm during a tool change and the recovery path is mostly known, the OEM manual just buries it under three layers of cross-referenced parameter tables.

What how to debug moveit 2 ompl planner failed to find motion plan after collision object add actually involves on ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026

On ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 on a fresh callout the tools I crack open first are rqt_graph and rqt_console for runtime error stream view, Foxglove Studio with rosbridge for live topic and parameter inspection, MoveIt 2 demo.launch.py with rviz2 MotionPlanning panel. Each of these surfaces a different layer of the fault - keep at least the first one in your fault-history notebook so the next time this happens you do not start cold.

For verification on ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026, the methods that survive contact with a real second-shift production workload are run ros2 doctor --report and check QOS_COMPATIBILITY warnings and trace executor latency with ros2 trace and analyze via tracetools_analysis. Anything less than that and you are shipping on vibes.

Authoritative sources for ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 that I cross-reference before committing to a fix: fast-dds.docs.eprosima.com, github.com, design.ros2.org. OEM marketing brochures and trade-press writeups are signal, not ground truth.

The rest of this page is the structured fix path. Start with diagnose, then remediation, then the automation options so you do not have to do this by hand the next time it surfaces. Verify and safety sections at the end are the discipline that keeps the fix from regressing the next time you open the cabinet.

Diagnose first, fix second

Eighth: diff the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 setup against its last known good state. Ask the obvious question - what changed in the 72 hours before the fault started? Did the controller take a firmware update overnight (check the About panel for the firmware revision vs the previous version you wrote down in your notes)? Did you swap a drive, a motor, an encoder cable, or a fieldbus drop? Did you change a tool offset, a work offset, a vision job, or a recipe? Did the maintenance team push a new PM checklist, swap a lube reservoir, or change a coolant concentration? Use the in-controller audit trail (Fanuc PARAM history, KUKA KRC log, Cognex In-Sight job version) to anchor "before vs after" so you are not guessing. Cross-check the OEM service bulletin and the OEM community forum for the exact firmware revision - if a regression hit a batch of cells in the same week, the community catches it before the official bulletin admits it. Record the suspect ranking, then disprove suspects one at a time with the cheapest test first (parameter restore before drive swap, encoder battery check before encoder swap).

Fourth: open the OEM service bulletin index for ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 and the upstream OEM hotline release notes for the failing window. The smoking guns are an open service bulletin touching the exact alarm class you are seeing, a recent retrofit kit covering the same symptom, or an OEM safety advisory on a partial firmware regression. Cross-reference the timestamp of your first faulted run against the bulletin issue date - if they match within the firmware revision window, stop debugging the cell and subscribe to the bulletin updates. Many OEMs lag the public bulletin index behind the actual field issue by weeks; if the OEM forum and the controls-community subreddits are both lit up but no bulletin is posted yet, trust the crowd and treat it as OEM-side until proven otherwise.

Fifth: replay the failing run against a second axis or a second controller on the same ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 cell. The point is to isolate "this drive" from "this controller" from "the whole cell." If a teammate identical sister-machine works but yours does not, the failure is local to the parameter set or the encoder cable. If the same program faults on every controller in the same cell, you have a cell-wide config change or an OEM-side firmware quirk. Pin the controller firmware version explicitly while you do this: the controller About panel, the firmware hash in the parameter dump, or the system version returned by a SCPI *IDN? query. The version pin is what isolates "the OEM update broke us" from "this machine is on an older firmware than the rest of the cell."

Field notes from real ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 callouts

When a ROS 2 Platform Error Codes fault code lights up on the panel, the first thing I reach for is rqt_graph and rqt_console for runtime error stream view, it tells me whether the signal is real or a sensor pretending to be sick. For Robotics jobs I keep a battered field notebook of "what bit me on ROS 2 Platform Error Codes and how I cleared it", writing it down the first time has saved me a dozen overnight returns. The Robotics side of ROS 2 Platform Error Codes evolves slowly on paper and fast in firmware, a vendor manual from two years ago is almost guaranteed to miss the new alarm codes.

Tools I actually reach for

For most ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 faults I start with ros2 doctor diagnostic CLI command, fall back to ros2 node list and ros2 lifecycle get for state machine snapshot, Cyclone DDS ddsperf and Fast DDS fastdds discovery server CLI, ros2 topic echo and ros2 topic info -v for QoS introspection when ros2 doctor diagnostic CLI command cannot surface the answer, and keep Nav2 nav2_lifecycle_manager CLI for bringup recovery handy for the cases where neither answers. That ordering is not academic - it matches the layers of the fault as they tend to surface, so the cheapest signal lands first and the heavier tooling only comes out when the simpler answer does not hold up. My muscle-memory shortcut for this is to run the first tool while the alarm screen is still open, not after I have already cycled controller power.

Verification I run before I call it fixed

Before I mark a ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 fault resolved, the verification loop below is what I actually run. Each step proves a different layer is green, and the order matters - the cheaper checks gate the more expensive ones.

check lifecycle node state with ros2 lifecycle get /node_name and force transition

If that one comes back clean, move to the next check. If it does not, stop and dig in there before layering more verification on top of a red signal.

run colcon test --packages-select <pkg> and inspect test_results XML

If that one comes back clean, move to the next check. If it does not, stop and dig in there before layering more verification on top of a red signal.

validate publisher and subscriber QoS profiles match via ros2 topic info /topic --verbose

If that one comes back clean, move to the next check. If it does not, stop and dig in there before layering more verification on top of a red signal.

run ros2 doctor --report and check QOS_COMPATIBILITY warnings

If that one comes back clean, move to the next check. If it does not, stop and dig in there before layering more verification on top of a red signal.

tail rosout via ros2 run rqt_console rqt_console during fault reproduction

Only when every line above runs clean do I close the loop and update my fault-history notebook with the timestamps.

Where I check first when the docs disagree

When two sources contradict each other on a ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 detail, the disambiguation order I lean on is stable. I usually check github.com for the ground-truth view on this part of ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026. I usually check fast-dds.docs.eprosima.com for the ground-truth view on this part of ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026. I usually check discourse.ros.org for the ground-truth view on this part of ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026. OEM marketing brochures and trade-press writeups are signal, not ground truth, and I treat them as such until the references above either confirm or contradict the claim.

Solution-focused remediation path

If the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller is slow, faulting on cached errors, or HMI-locked, work the cache and parameter stack in order. Cycle controller power per the OEM lockout procedure (master disconnect off, wait 60 seconds for bus discharge, master disconnect on), reboot, and re-home the axes. Clear the local fault history (most controllers expose this under Maintenance -> Clear faults, or Setup -> Reset alarms). Re-load the saved parameter set with the OEM utility (Fanuc PARAM RESTORE, KUKA archive restore) to bypass any local parameter drift. Always capture timing before the cycle: time how long the failing cycle takes three times, write it down, then repeat after the parameter restore so the delta is provable in your notes. Decision point: managed-cell issues go through your controls engineering team for a cell-wide config push; standalone-cell issues go through the OEM diagnostic utility before you escalate to the OEM hotline.

For ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 cells where duty-cycle limits or thermal envelopes are suspect, read the in-controller hints honestly. "Servo overcurrent" usually means you hit the peak current envelope of the drive during accel. "Motor overload" is the sustained-thermal signal on the motor winding. "Drive overheat" is the heatsink thermistor signal. Each is telling you the exact same thing in a ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026-specific dialect. Apply duty-cycle dwell for repeated-cycle programs (insert a 500ms dwell between high-load moves), reduce the rapid feedrate, and chunk a long cycle into smaller passes. Decision point: if you are hitting the thermal limit sustained rather than in bursts, the cell is undersized for the workpiece - upgrade the drive amperage rating or request a thermal margin review from the OEM with a written duty-cycle analysis; without it, dial back the throughput at the cell. Replay the failing program against a fresh test workpiece at half the feedrate to confirm the new safe envelope before pushing to the production cell.

When the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller returns intermittent alarms, cycle delays, or "something went wrong" under normal load, suspect the OEM firmware or a wiring intermittent before blaming the cell. Subscribe to the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 OEM service bulletin RSS or hotline notification so an open bulletin lights up your inbox or Teams automatically. Cross-check the OEM Trust Center or maintenance portal for any planned firmware push covering your machine series. Listen to the OEM controls-community forum and r/ros - many regressions land there 15 to 30 minutes before the formal bulletin update. Decision point: if no bulletin is open but multiple teammates in the same plant are seeing the same alarm, fail over to a sister cell (if a sister machine exists) or to a backup parameter set (if the saved archive is current) and file an OEM service ticket with the alarm history dump, the controller serial number, and the timestamp window; major OEMs all accept the controller serial number as the primary trace key. Photograph the faulting cell with the HMI and the firmware version visible before the failover - that photo is what the OEM field service engineer asks for first on any alarm or cycle-time complaint.

Automate this fix so you do not do it twice

Monitor + alert via ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 OEM diagnostic reports, alarm history, and plant dashboard ingestion

For the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026, the most useful long-running telemetry is the OEM diagnostic reports + alarm history shipped to a plant dashboard (Grafana with a CSV source, Ignition with a tag history, the fab MES OEE per SEMI E10, a Notion database via the API) and graphed on a single view. Pair that with synthetic monitoring (a small script that triggers the failing cycle or runs the failing test sequence every 5 minutes from at least two cells) so a fleet-level regression lights up before teammates report it. Subscribe the on-call inbox or a private Teams channel to the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 OEM service bulletin (Atom/RSS or vendor portal webhook) plus the OEM service-status handle so an open bulletin self-correlates with the synthetic failures.

# Tiny synthetic monitor - hit the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller health endpoint every 5 minutes
while true; do curl -s -o /dev/null -w "%{http_code} %{time_total} $(date -Iseconds)\n" \ -H "Authorization: Bearer $TOKEN" \ https://controller.plant.local/api/v1/me \ >> /var/log/ros-synth.log sleep 300
done

Scrape ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller alarm history + fieldbus log via scheduled job

For the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026, cell faults usually surface as drive alarms, fieldbus dropouts, or vision-trigger misses before a full line stoppage. A weekly scheduled job that exports the last 7 days of these events to CSV gives you a paper trail to correlate with firmware updates, parameter edits, and OEM bulletins without staring at the HMI live. Register the task via cron on a plant-floor logger PC (Linux IPC), Windows Task Scheduler (schtasks /create /XML) on an engineering workstation, or a GitHub Actions schedule against a cell-controller API, then write the CSV to a plant file share or the fab MES for retention. Subscribe a simple dashboard (Grafana with a CSV source, Ignition with a tag history, the fab MES OEE report) to the same bucket so alarm events from every ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller converge on a single view without per-cell HMI clicking.

# Export the controller alarm history via the OEM API (if supported)
curl -X POST https://controller.plant.local/api/v1/alarm_history \ -H "Authorization: Bearer $CONTROLLER_TOKEN" \ -H "Accept: application/json" \ -d '{"start_date":"2026-05-25","end_date":"2026-06-01"}' \ -o ros-alarm-history.json
# Export the cycle history for the last 7 days
curl -G https://controller.plant.local/api/v1/cycles \ -H "Authorization: Bearer $CONTROLLER_TOKEN" \ --data-urlencode "oldest=$(date -d '7 days ago' +%s)" \ -o ros-cycles.json

Multi-cell rate-limit + retry policy via shared client wrapper

When the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 integration runs across multiple cells or controller types, every consumer needs the same backoff, jitter, and idempotency behavior or one noisy cell will starve the rest of the MES poller. Wrap the OEM SDK or fetch call in a thin client that reads the rate-limit headers (X-RateLimit-Remaining, Retry-After, x-ratelimit-reset), applies full jitter (base 200ms, cap 30s, max 5 retries), and de-dupes writes by a stable key (the controller cycle id, the fieldbus drop external id, the destination MES record id). Emit simple log lines tagged with the cell id so a fieldbus burst on one cell shows up in the same log as the downstream cascade.

# Python - ros controller API wrapper with full-jitter retry
from tenacity import retry, wait_random_exponential, stop_after_attempt, retry_if_exception_type
import requests class RateLimited(Exception): pass @retry( wait=wait_random_exponential(multiplier=0.2, max=30), stop=stop_after_attempt(5), retry=retry_if_exception_type(RateLimited),
)
def call_ros(method, path, token, payload=None): r = requests.request(method, f"https://controller.plant.local{path}", headers={"Authorization": f"Bearer {token}"}, json=payload, timeout=10) if r.status_code == 429: raise RateLimited(r.headers.get("Retry-After")) r.raise_for_status() return r.json()

Common pitfalls and what to watch for

Read-only validation before any write is the single step most ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 fixes skip, and it is the step that lets you roll back when a fix backfires. Photograph every existing parameter page (the axis parameters, the spindle parameters, the safety parameters, the I/O mapping, the recipe library), capture the failing photo in a notes entry, export the relevant log to CSV if the controller supports it (the OEM diagnostic tool fault-history export, the PMC log download), and photograph the HMI alarm history showing the failing window before any change. On ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 cells with multiple operating modes (manual jog, MDI, auto) record the firmware revision, the parameter state, and the I/O mapping in each before toggling anything, because a "fix" pushed only to manual mode is a known regression vector when auto mode has a different interlock set.

The mirror-image mistake is confusing a cell-level symptom with an OEM fault on ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026. A persistent SRVO-023 is often a workpiece-level change pushed by the production team rather than a ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 bug. A "program not loading" can be a renamed program rather than a deleted one. A "trigger not firing" is frequently a vibrated-loose sensor cable or a contaminated lens rather than an OEM-side regression.

Verify the fix worked

• Reproduce the original faulting cycle against ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 on the same cell AND a sister cell with the same recipe. If the alarm or fault code still surfaces on any cell, you have not fixed it.
• Watch for 24 to 48 hours via the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller alarm history + the fieldbus log + your fault-history notebook. Cached fault states and stale fieldbus link state mask slow-burn drift and intermittent fieldbus issues.
• Smoke-test under realistic load: replay the cycle against a test workpiece for at least 30 minutes at your normal production feedrate, log success / alarm and the timestamp per attempt to a notes file.
• Capture the new state in a fault-history notebook entry so the next time this happens you do not rediscover it. Note firmware revision + parameter set + I/O mapping + failing photo + verbatim alarm string + fix applied. Push to a plant-wide maintenance wiki if your plant uses one.
• If the fix involved a maintenance-token rotation or a parameter set change, commit the new token to your password manager and photograph the parameter dump for archival.

Safety, rollback, blast radius

• Test in a ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 maintenance mode or on a sister cell first before any change that touches the production cell. Snapshot the firmware revision, the parameter set, the I/O mapping, and the safety-PLC permissions before changing anything.
• Apply the principle of least surprise when granting teach-pendant access or safety-PLC permissions. Review the operator roster against the people who actually need access - extra teach pendants are extra blast radius.
• Use idempotent cycles where the ROS 2 Platform Error Codes, rclcpp/rclpy, DDS QoS, Lifecycle Nodes, MoveIt 2, 2026 controller supports it (the OEM cycle-id de-dupe, external id keys on MES records) so a re-run cycle does not double-count parts or duplicate scrap records.
• Know your rollback path. Firmware rollback is a one-line OEM utility load; a maintenance-token rotation is reversible if you kept the old token in the password manager during cutover; a parameter set change is reversible only if you saved the previous archive.
• For cell-wide or plant-wide changes, line up a maintenance window with production scheduling before pushing through the OEM utility.

FAQ

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