feat(api, app): add disable Flex Stacker labware detection as a feature flag (#19116)

# Overview
This PR adds the ability to disable labware detection on the stackers
during a protocol run as a robot settings feature flag. This can be
useful when working with labware whose reflectivity falls outside our
validated range, or in cases where the sensors are malfunctioning.

Author: ahiuchingau

api/src/opentrons/config/advanced_settings.py

@@ -222,6 +222,14 @@ class Setting(NamedTuple):
         robot_type=[RobotTypeEnum.OT2, RobotTypeEnum.FLEX],
         internal_only=True,
     ),
+    SettingDefinition(
+        _id="disableFlexStackerLabwareDetection",
+        title="Disable Flex Stacker's labware detection features",
+        description=(
+            "Flex Stackers will ignore labware's presence in the hopper and on the shuttle. Protocol runs will no longer raise the following recoverable errors: Hopper Empty, Shuttle Empty and Shuttle Occupied."
+        ),
+        robot_type=[RobotTypeEnum.FLEX],
+    ),
 ]
 
 
@@ -733,6 +741,16 @@ def _migrate36to37(previous: SettingsMap) -> SettingsMap:
     return {k: v for k, v in previous.items() if "allowLiquidClasses" != k}
 
 
+def _migrate37to38(previous: SettingsMap) -> SettingsMap:
+    """Migrate to version 36 of the feature flags file.
+
+    -  Adds the disableFlexStackerLabwareDetection config element.
+    """
+    newmap = {k: v for k, v in previous.items()}
+    newmap["disableFlexStackerLabwareDetection"] = None
+    return newmap
+
+
 _MIGRATIONS = [
     _migrate0to1,
     _migrate1to2,
@@ -771,6 +789,7 @@ def _migrate36to37(previous: SettingsMap) -> SettingsMap:
     _migrate34to35,
     _migrate35to36,
     _migrate36to37,
+    _migrate37to38,
 ]
 """
 List of all migrations to apply, indexed by (version - 1). See _migrate below

api/src/opentrons/config/feature_flags.py

@@ -78,3 +78,9 @@ def enable_performance_metrics(robot_type: RobotTypeEnum) -> bool:
 
 def oem_mode_enabled() -> bool:
     return advs.get_setting_with_env_overload("enableOEMMode", RobotTypeEnum.FLEX)
+
+
+def flex_stacker_tof_sensors_disabled() -> bool:
+    return advs.get_setting_with_env_overload(
+        "disableFlexStackerLabwareDetection", RobotTypeEnum.FLEX
+    )

api/src/opentrons/hardware_control/modules/flex_stacker.py

@@ -53,6 +53,7 @@
     FlexStackerData,
 )
 from opentrons.hardware_control.types import StatusBarState, StatusBarUpdateEvent
+from opentrons.config import feature_flags as ff
 
 from opentrons_shared_data.errors.exceptions import (
     FlexStackerStallError,
@@ -730,6 +731,8 @@ async def verify_shuttle_labware_presence(
         self, direction: Direction, labware_expected: bool
     ) -> None:
         """Check whether or not a labware is detected on the shuttle."""
+        if ff.flex_stacker_tof_sensors_disabled():
+            return
         result = await self.labware_detected(StackerAxis.X, direction)
         if labware_expected != result:
             if labware_expected:
@@ -748,6 +751,8 @@ async def verify_hopper_labware_presence(
         self, direction: Direction, labware_expected: bool
     ) -> None:
         """Check whether or not a labware is detected inside the hopper."""
+        if ff.flex_stacker_tof_sensors_disabled():
+            return
         result = await self.labware_detected(StackerAxis.Z, direction)
         if labware_expected != result:
             raise FlexStackerHopperLabwareError(

api/tests/opentrons/config/test_advanced_settings_migration.py

@@ -8,7 +8,7 @@
 
 @pytest.fixture
 def migrated_file_version() -> int:
-    return 37
+    return 38
 
 
 # make sure to set a boolean value in default_file_settings only if
@@ -30,6 +30,7 @@ def default_file_settings() -> Dict[str, Any]:
         "enableErrorRecoveryExperiments": None,
         "enableOEMMode": None,
         "enablePerformanceMetrics": None,
+        "disableFlexStackerLabwareDetection": None,
     }
 
 
@@ -438,6 +439,18 @@ def v37_config(v36_config: Dict[str, Any]) -> Dict[str, Any]:
     return r
 
 
+@pytest.fixture
+def v38_config(v37_config: Dict[str, Any]) -> Dict[str, Any]:
+    r = v37_config.copy()
+    r.update(
+        {
+            "_version": 38,
+            "disableFlexStackerLabwareDetection": None,
+        }
+    )
+    return r
+
+
 @pytest.fixture(
     params=[
         lazy_fixture("empty_settings"),
@@ -479,6 +492,7 @@ def v37_config(v36_config: Dict[str, Any]) -> Dict[str, Any]:
         lazy_fixture("v35_config"),
         lazy_fixture("v36_config"),
         lazy_fixture("v37_config"),
+        lazy_fixture("v38_config"),
     ],
 )
 def old_settings(request: SubRequest) -> Dict[str, Any]:
@@ -569,4 +583,5 @@ def test_ensures_config() -> None:
         "enableErrorRecoveryExperiments": None,
         "enableOEMMode": None,
         "enablePerformanceMetrics": None,
+        "disableFlexStackerLabwareDetection": None,
     }

app/index.html

@@ -1,10 +1,13 @@
-<!doctype html>
+<!DOCTYPE html>
 <html lang="en">
   <head>
     <meta charset="UTF-8" />
-    <meta name='viewport' content='width=device-width,initial-scale=1'>
+    <meta name="viewport" content="width=device-width,initial-scale=1" />
 
-    <link href="https://fonts.googleapis.com/css?family=Open+Sans:400,400i,600,600i,700,700i" rel="stylesheet">
+    <link
+      href="https://fonts.googleapis.com/css?family=Open+Sans:400,400i,600,600i,700,700i"
+      rel="stylesheet"
+    />
 
     <meta name="viewport" content="width=device-width, initial-scale=1.0" />
     <title>Opentrons</title>

app/src/assets/localization/en/device_settings.json

@@ -91,6 +91,8 @@
   "device_reset_slideout_description": "Select individual settings to only clear specific data types.",
   "device_resets_cannot_be_undone": "Resets cannot be undone",
   "directly_connected_to_this_computer": "Directly connected to this computer.",
+  "disable_stacker_sensors": "Disable Stacker sensors for labware detection in z-axis and x-axis",
+  "disable_stacker_sensors_description": "Disable sensors for all stackers that are connected to the robot.",
   "disconnect": "Disconnect",
   "disconnect_from_ssid": "Disconnect from {{ssid}}",
   "disconnect_from_wifi": "Disconnect from Wi-Fi",

app/src/atoms/SoftwareKeyboard/index.css

@@ -7,14 +7,8 @@
   padding: 5px;
   border-radius: 5px;
   background-color: #ececec;
-  font-family:
-    HelveticaNeue-Light,
-    Helvetica Neue Light,
-    Helvetica Neue,
-    Helvetica,
-    Arial,
-    Lucida Grande,
-    sans-serif;
+  font-family: HelveticaNeue-Light, Helvetica Neue Light, Helvetica Neue,
+    Helvetica, Arial, Lucida Grande, sans-serif;
   touch-action: manipulation;
   -webkit-user-select: none;
   -moz-user-select: none;

app/src/organisms/Desktop/Devices/RobotSettings/AdvancedTab/DisableStackerSensors.tsx

@@ -0,0 +1,51 @@
+import { useTranslation } from 'react-i18next'
+
+import {
+  ALIGN_CENTER,
+  Box,
+  Flex,
+  JUSTIFY_SPACE_BETWEEN,
+  LegacyStyledText,
+  SPACING,
+  TYPOGRAPHY,
+} from '@opentrons/components'
+
+import { ToggleButton } from '/app/atoms/buttons'
+import { useDisableStackerSensors } from '/app/resources/robot-settings'
+
+interface DisableStackerSensorsProps {
+  robotName: string
+  isRobotBusy: boolean
+}
+
+export function DisableStackerSensors({
+  robotName,
+  isRobotBusy,
+}: DisableStackerSensorsProps): JSX.Element {
+  const { t } = useTranslation('device_settings')
+  const { sensorsDisabled, toggleSensors } = useDisableStackerSensors(robotName)
+
+  return (
+    <Flex alignItems={ALIGN_CENTER} justifyContent={JUSTIFY_SPACE_BETWEEN}>
+      <Box width="70%">
+        <LegacyStyledText
+          css={TYPOGRAPHY.pSemiBold}
+          paddingBottom={SPACING.spacing4}
+          id="AdvancedSettings_disableStackerSensors"
+        >
+          {t('disable_stacker_sensors')}
+        </LegacyStyledText>
+        <LegacyStyledText as="p">
+          {t('disable_stacker_sensors_description')}
+        </LegacyStyledText>
+      </Box>
+      <ToggleButton
+        label="disable_stacker_sensors"
+        toggledOn={sensorsDisabled}
+        onClick={toggleSensors}
+        id="RobotSettings_DisableStackerSensorsToggleButton"
+        disabled={isRobotBusy}
+      />
+    </Flex>
+  )
+}

app/src/organisms/Desktop/Devices/RobotSettings/AdvancedTab/__tests__/DisableStackerSensors.test.tsx

@@ -0,0 +1,63 @@
+import { fireEvent, screen } from '@testing-library/react'
+import { beforeEach, describe, expect, it, vi } from 'vitest'
+
+import '@testing-library/jest-dom/vitest'
+
+import { renderWithProviders } from '/app/__testing-utils__'
+import { i18n } from '/app/i18n'
+import { useDisableStackerSensors } from '/app/resources/robot-settings'
+
+import { DisableStackerSensors } from '../DisableStackerSensors'
+
+import type { ComponentProps } from 'react'
+
+vi.mock('/app/resources/robot-settings')
+
+const ROBOT_NAME = 'otie'
+const mockToggleSensors = vi.fn()
+const render = (props: ComponentProps<typeof DisableStackerSensors>) => {
+  return renderWithProviders(<DisableStackerSensors {...props} />, {
+    i18nInstance: i18n,
+  })
+}
+
+describe('DisableStackerSensors', () => {
+  let props: ComponentProps<typeof DisableStackerSensors>
+
+  beforeEach(() => {
+    props = {
+      robotName: ROBOT_NAME,
+      isRobotBusy: false,
+    }
+    vi.mocked(useDisableStackerSensors).mockReturnValue({
+      sensorsDisabled: false,
+      toggleSensors: mockToggleSensors,
+    })
+  })
+
+  it('should render text and toggle button', () => {
+    render(props)
+    screen.getByText(
+      'Disable Stacker sensors for labware detection in z-axis and x-axis'
+    )
+    screen.getByText(
+      'Disable sensors for all stackers that are connected to the robot.'
+    )
+    expect(screen.getByLabelText('disable_stacker_sensors')).toBeInTheDocument()
+  })
+
+  it('should call a mock function when clicking toggle button', () => {
+    render(props)
+    fireEvent.click(screen.getByLabelText('disable_stacker_sensors'))
+    expect(mockToggleSensors).toHaveBeenCalled()
+  })
+
+  it('shoud make toggle button disabled when robot is busy', () => {
+    props = {
+      ...props,
+      isRobotBusy: true,
+    }
+    render(props)
+    expect(screen.getByLabelText('disable_stacker_sensors')).toBeDisabled()
+  })
+})

app/src/organisms/Desktop/Devices/RobotSettings/AdvancedTab/index.ts

@@ -1,5 +1,6 @@
 export * from './DeviceReset'
 export * from './DisplayRobotName'
+export * from './DisableStackerSensors'
 export * from './EnableStatusLight'
 export * from './FactoryMode'
 export * from './GantryHoming'