Catch all cases where the z height of the bottom of attached tips wou…

…ld be lower than the top of gripped labware

api/src/opentrons/protocol_engine/commands/move_labware.py

@@ -2,7 +2,7 @@
 
 from __future__ import annotations
 from pydantic import BaseModel, Field
-from typing import TYPE_CHECKING, Optional, Type
+from typing import TYPE_CHECKING, Optional, Type, List
 from typing_extensions import Literal
 
 from opentrons.types import Point
@@ -199,6 +199,7 @@ async def execute(  # noqa: C901
                 pickUpOffset=params.pickUpOffset or LabwareOffsetVector(x=0, y=0, z=0),
                 dropOffset=params.dropOffset or LabwareOffsetVector(x=0, y=0, z=0),
             )
+
             # Skips gripper moves when using virtual gripper
             await self._labware_movement.move_labware_with_gripper(
                 labware_id=params.labwareId,

api/src/opentrons/protocol_engine/execution/labware_movement.py

@@ -79,7 +79,7 @@ def __init__(
             )
         )
 
-    async def move_labware_with_gripper(
+    async def move_labware_with_gripper(  # noqa: C901
         self,
         labware_id: str,
         current_location: OnDeckLabwareLocation,
@@ -89,8 +89,25 @@ async def move_labware_with_gripper(
     ) -> None:
         """Move a loaded labware from one location to another using gripper."""
         use_virtual_gripper = self._state_store.config.use_virtual_gripper
+
         if use_virtual_gripper:
+            # During Analysis we will pass in hard coded estimates for certain positions on accessible during execution
+            # Estimated gripper homed position Z: 253.575 + 93.85 - 94.825 - 86.475 = 166.125 mm
+            attached_tips = self._state_store.pipettes.get_all_attached_tips()
+            if attached_tips:
+                for pipette_id, tip in attached_tips:
+                    if not self._state_store.geometry.validate_gripper_labware_tip_collision(
+                        gripper_homed_position_z=166.125,
+                        pipettes_homed_position_z=248.0,
+                        tip=tip,
+                        labware_id=labware_id,
+                        current_location=current_location,
+                    ):
+                        raise LabwareMovementNotAllowedError(
+                            f"Cannot move labware '{self._state_store.labware.get(labware_id).loadName}' when {int(tip.volume)} ul tips are attached."
+                        )
             return
+
         ot3api = ensure_ot3_hardware(
             hardware_api=self._hardware_api,
             error_msg="Gripper is only available on Opentrons Flex",
@@ -111,6 +128,23 @@ async def move_labware_with_gripper(
         await ot3api.home(axes=[Axis.Z_L, Axis.Z_R, Axis.Z_G])
         gripper_homed_position = await ot3api.gantry_position(mount=gripper_mount)
 
+        # Verify that no tip collisions will occur during the move
+        attached_tips = self._state_store.pipettes.get_all_attached_tips()
+        if attached_tips:
+            for pipette_id, tip in attached_tips:
+                pipetted_homed_position = await ot3api.gantry_position(mount=self._state_store.pipettes.get_mount(pipette_id))
+
+                if not self._state_store.geometry.validate_gripper_labware_tip_collision(
+                    gripper_homed_position_z=gripper_homed_position.z,
+                    pipettes_homed_position_z=pipetted_homed_position.z,
+                    tip=tip,
+                    labware_id=labware_id,
+                    current_location=current_location,
+                ):
+                    raise LabwareMovementNotAllowedError(
+                        f"Cannot move labware '{self._state_store.labware.get(labware_id).loadName}' when {int(tip.volume)} ul tips are attached."
+                    )
+
         async with self._thermocycler_plate_lifter.lift_plate_for_labware_movement(
             labware_location=current_location
         ):

api/src/opentrons/protocol_engine/state/geometry.py

@@ -6,6 +6,7 @@
 from opentrons.types import Point, DeckSlotName, StagingSlotName, MountType
 from opentrons_shared_data.labware.constants import WELL_NAME_PATTERN
 
+
 from .. import errors
 from ..errors import LabwareNotLoadedOnLabwareError, LabwareNotLoadedOnModuleError
 from ..resources import fixture_validation
@@ -977,6 +978,28 @@ def get_total_nominal_gripper_offset_for_move_type(
                     ).dropOffset
                 )
 
+    def validate_gripper_labware_tip_collision(
+        self,
+        gripper_homed_position_z: float,
+        pipettes_homed_position_z: float,
+        tip: TipGeometry,
+        labware_id: str,
+        current_location: OnDeckLabwareLocation,
+    ) -> bool:
+        """Check for potential collision of tips against labware to be lifted."""
+        labware_top_z_when_gripped = gripper_homed_position_z + (
+            self.get_labware_highest_z(labware_id=labware_id)
+            - self.get_labware_grip_point(
+                labware_id=labware_id, location=current_location
+            ).z
+        )
+        # TODO(mm, 2024-01-18): Utilizing the nozzle map and labware X coordinates verify if collisions will occur on the X axis (analysis will use hard coded data to measure from the gripper critical point to the pipette mount)
+
+        tip_bottom_z = pipettes_homed_position_z - tip.length
+        if tip_bottom_z < labware_top_z_when_gripped:
+            return False
+        return True
+
     def _nominal_gripper_offsets_for_location(
         self, location: OnDeckLabwareLocation
     ) -> LabwareMovementOffsetData: