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bug: Incorrectly loading labware can cause the robot to crash and the robot will not know it #20213

@Talothyn

Description

@Talothyn

Overview

Ok, this partially occurred because I messed up, but I set up a protocol to transfer liquid from a 96 well opentrons PCR plate to another plate.
However, the source plate was located on a thermal module, and the aluminum block to hold the plate was also on that module.
Unfortunately, although the API DID know about the thermo module, it did not get notified of the aluminum block.

The result: The robot crashed a tip through the bottom of a well on the source plate.
The thing is, the robot never sensed anything wrong. It should have had a pressure sensor detect something, similar to the over-pressure warnings used when it punches through a plate seal, and warned or stopped the protocol, but it did not.
Thankfully we were watching it and were able to stop it before anything else got damaged and just had to clean up a bit, but I think that if there is a mistake, and the robot is going to, or does, crash in to the bottom of a plate, it should detect that and stop.

Steps to reproduce

Program a liquid transfer where the source plate is on a thermo module, on the aluminum block, but do not tell the robot that the aluminum block is there.

Current behavior

The pipette will crash through the bottom of the plate and not even notice. This will both break your plate and crush the pipette tip you are using. But the robot will keep going if you are not in the room.

Expected behavior

When something like this happens, I would want the robot to detect that it has crashed and at least pause it's current protocol.

Operating system

None

System and robot setup or anything else?

No response

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