fix(api): bump y max bounds to match robot geometry

We now helpfully check that jogs don't overlap the maximum motion range
of each axis, at least in the positive direction, using the home
positions. This works pretty well for Z and X since it straightforwardly
prevents hard limit errors from unintentional endstop triggers, which
happen at the home position as one might expect.

Unfortunately, the robot geometry makes this approach completely invalid
for Y. When homing, the Y endstop (which is located on the back of the
head) actually interacts with a post projecting from the back of the
robot, which is located on the right side of the robot. This is the
reason we must always home X before homing Y: to make sure the head is
in the correct position for the Y endstop to interact with the post.

If the head is _not_ all the way to the right, it can actually go much
farther back - past the home location, past where the switch would
interact with the post. And the deck layout is designed to take
advantage of this; the position that A1 of most labware lives in is
farther back than the post, and thus customers would get spurious jog
failures when calibrating labwares in slots 10 and 11 using single
channel pipettes (because multi channels are wider in Y, the gantry
doesn't go far enough back to trigger the issue).

The fix is to create a different bound in the Y.

Closes #6886

api/src/opentrons/drivers/smoothie_drivers/driver_3_0.py

@@ -5,6 +5,9 @@
 from time import sleep, time
 from threading import Event, RLock
 from typing import Any, Dict, Optional, Union, List, Tuple, cast
+from typing import Any, Dict, Optional, Union, List, Tuple, cast
+from typing_extensions import Final
+
 from math import isclose
 from serial.serialutil import SerialException  # type: ignore
 
@@ -33,14 +36,15 @@
 
 
 # TODO (artyom, ben 20171026): move to config
-HOMED_POSITION: Dict[str, float] = {
-    'X': 418,
-    'Y': 353,
-    'Z': 218,
-    'A': 218,
-    'B': 19,
-    'C': 19
+HOMED_POSITION: Final = {
+    'X': 418.0,
+    'Y': 353.0,
+    'Z': 218.0,
+    'A': 218.0,
+    'B': 19.0,
+    'C': 19.0
 }
+Y_BOUND_OVERRIDE: Final = 370
 
 
 PLUNGER_BACKLASH_MM = 0.3
@@ -415,9 +419,15 @@ def gpio_chardev(self, gpio_chardev):
         self._gpio_chardev = gpio_chardev
 
     @property
-    def homed_position(self):
+    def homed_position(self) -> Dict[str, float]:
         return self._homed_position.copy()
 
+    @property
+    def axis_bounds(self) -> Dict[str, float]:
+        bounds = {k: v for k, v in self._homed_position.items()}
+        bounds['Y'] = Y_BOUND_OVERRIDE
+        return bounds
+
     def _update_position(self, target):
         self._position.update({
             axis: value

api/src/opentrons/hardware_control/controller.py

@@ -263,7 +263,7 @@ async def connect(self, port: str = None):
     def axis_bounds(self) -> Dict[Axis, Tuple[float, float]]:
         """ The (minimum, maximum) bounds for each axis. """
         return {Axis[ax]: (0, pos) for ax, pos
-                in self._smoothie_driver.homed_position.items()
+                in self._smoothie_driver.axis_bounds.items()
                 if ax not in 'BC'}
 
     @property

api/src/opentrons/hardware_control/simulator.py

@@ -36,7 +36,10 @@
 MODULE_LOG = logging.getLogger(__name__)
 
 
-_HOME_POSITION = {'X': 418.0, 'Y': 353.0, 'Z': 218.0,
+_HOME_POSITION: Final = {'X': 418.0, 'Y': 353.0, 'Z': 218.0,
+                         'A': 218.0, 'B': 19.0, 'C': 19.0}
+
+_BOUNDS: Final = {'X': 418.0, 'Y': 370.0, 'Z': 218.0,
                   'A': 218.0, 'B': 19.0, 'C': 19.0}
 
 
@@ -288,7 +291,7 @@ async def build_module(
     @property
     def axis_bounds(self) -> Dict[Axis, Tuple[float, float]]:
         """ The (minimum, maximum) bounds for each axis. """
-        return {Axis[ax]: (0, pos) for ax, pos in _HOME_POSITION.items()
+        return {Axis[ax]: (0, pos) for ax, pos in _BOUNDS.items()
                 if ax not in 'BC'}
 
     @property

api/src/opentrons/tools/overnight_test.py

@@ -29,8 +29,8 @@
 attempts_to_home = 1
 too_many_attempts_to_home = 3
 
-XY_TOLERANCE = 30
-ZA_TOLERANCE = 10
+XY_TOLERANCE = 30.0
+ZA_TOLERANCE = 10.0
 
 AXIS_TEST_SKIPPING_TOLERANCE = 0.5