fix(api,shared-data): various FlexStacker fixes and adjustments

- increased flex stacker z current from 1.5mA to 1.8mA to account for full tipracks
- increased the offset used when moving the z axis for storing tall labware like tipracks
- added await get_motion_params call when initializing the move_params in the FlexStacker module.
- added lid height if lid is used in the retrieve.py and store.py commands.
- exclude lids on top of tipracks in the Flex Stacker when getting the highest z.
- add flexStackerModuleV1D4 addressable area to the flex stacker + wate chute fixture
- adjust the stackingOffsetWithLabware z from 8.193 to 14 for `opentrons_flex_tiprack_lid`
- decrease the `gripHeightFromLabwareTop from 8 to 4 for `opentrons_flex_tiprack_lid``

api/src/opentrons/drivers/flex_stacker/driver.py

@@ -52,14 +52,14 @@
             max_speed=10.0,
             acceleration=100.0,
             max_speed_discont=40,
-            current=1.5,
+            current=1.8,
         ),
         "move": MoveParams(
             StackerAxis.Z,
             max_speed=200.0,
             acceleration=500.0,
             max_speed_discont=40,
-            current=1.5,
+            current=1.8,
         ),
     },
     StackerAxis.L: {

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

@@ -344,7 +344,8 @@ async def store_labware(self, labware_height: float) -> bool:
         await self._prepare_for_action()
 
         # Move X then Z axis
-        distance = MAX_TRAVEL[StackerAxis.Z] - (labware_height / 2) - OFFSET_MD
+        offset = OFFSET_MD if labware_height < 20 else OFFSET_LG * 2
+        distance = MAX_TRAVEL[StackerAxis.Z] - (labware_height / 2) - offset
         await self._move_and_home_axis(StackerAxis.X, Direction.RETRACT, OFFSET_SM)
         await self.move_axis(StackerAxis.Z, Direction.EXTENT, distance)
 
@@ -410,7 +411,7 @@ async def get_limit_switch_status(self) -> None:
     async def get_motion_parameters(self) -> None:
         """Get the motion parameters used by the axis motors."""
         self.move_params = {
-            axis: self._driver.get_motion_params(axis) for axis in StackerAxis
+            axis: await self._driver.get_motion_params(axis) for axis in StackerAxis
         }
 
     async def get_platform_sensor_state(self) -> None:

api/src/opentrons/protocol_engine/commands/flex_stacker/retrieve.py

@@ -83,11 +83,16 @@ async def execute(self, params: RetrieveParams) -> SuccessData[RetrieveResult]:
         # Get the labware dimensions for the labware being retrieved,
         # which is the first one in the hopper labware id list
         lw_id = stacker_state.hopper_labware_ids[0]
-        lw_dim = self._state_view.labware.get_dimensions(labware_id=lw_id)
-
         if stacker_hw is not None:
-            # Dispense the labware from the Flex Stacker using the labware height
-            await stacker_hw.dispense_labware(labware_height=lw_dim.z)
+            labware = self._state_view.labware.get(lw_id)
+            labware_height = self._state_view.labware.get_dimensions(labware_id=lw_id).z
+            if labware.lid_id is not None:
+                lid_def = self._state_view.labware.get_definition(labware.lid_id)
+                offset = self._state_view.labware.get_labware_overlap_offsets(
+                    lid_def, labware.loadName
+                ).z
+                labware_height = labware_height + lid_def.dimensions.zDimension - offset
+            await stacker_hw.dispense_labware(labware_height=labware_height)
 
         # update the state to reflect the labware is now in the flex stacker slot
         state_update.set_labware_location(

api/src/opentrons/protocol_engine/commands/flex_stacker/store.py

@@ -68,12 +68,19 @@ async def execute(self, params: StoreParams) -> SuccessData[StoreResult]:
                 "Cannot store labware if Flex Stacker carriage is empty"
             )
 
-        lw_dim = self._state_view.labware.get_dimensions(labware_id=lw_id)
         # TODO: check the type of the labware should match that already in the stack
         state_update = update_types.StateUpdate()
 
         if stacker_hw is not None:
-            await stacker_hw.store_labware(labware_height=lw_dim.z)
+            labware = self._state_view.labware.get(lw_id)
+            labware_height = self._state_view.labware.get_dimensions(labware_id=lw_id).z
+            if labware.lid_id is not None:
+                lid_def = self._state_view.labware.get_definition(labware.lid_id)
+                offset = self._state_view.labware.get_labware_overlap_offsets(
+                    lid_def, labware.loadName
+                ).z
+                labware_height = labware_height + lid_def.dimensions.zDimension - offset
+            await stacker_hw.store_labware(labware_height=labware_height)
 
         # update the state to reflect the labware is store in the stack
         state_update.set_labware_location(

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

@@ -161,6 +161,7 @@ def get_all_obstacle_highest_z(self) -> float:
                 self._get_highest_z_from_labware_data(lw_data)
                 for lw_data in self._labware.get_all()
                 if lw_data.location != OFF_DECK_LOCATION
+                and not self._labware.get_labware_by_lid_id(lw_data.id)
             ),
             default=0.0,
         )

api/tests/opentrons/protocol_engine/commands/flex_stacker/test_retrieve.py

@@ -1,9 +1,10 @@
 """Test Flex Stacker retrieve command implementation."""
-from decoy import Decoy
 import pytest
+from decoy import Decoy
 from contextlib import nullcontext as does_not_raise
 from typing import ContextManager, Any
 
+from opentrons.calibration_storage.helpers import uri_from_details
 from opentrons.hardware_control.modules import FlexStacker
 
 from opentrons.protocol_engine.state.state import StateView
@@ -21,8 +22,17 @@
 from opentrons.protocol_engine.commands import flex_stacker
 from opentrons.protocol_engine.commands.command import SuccessData
 from opentrons.protocol_engine.commands.flex_stacker.retrieve import RetrieveImpl
-from opentrons.protocol_engine.types import Dimensions, ModuleLocation
+from opentrons.protocol_engine.types import (
+    DeckSlotLocation,
+    Dimensions,
+    ModuleLocation,
+    LoadedLabware,
+    OverlapOffset,
+)
 from opentrons.protocol_engine.errors import CannotPerformModuleAction
+from opentrons.types import DeckSlotName
+
+from opentrons_shared_data.labware.labware_definition import LabwareDefinition
 
 
 @pytest.mark.parametrize(
@@ -44,6 +54,7 @@ async def test_retrieve(
     equipment: EquipmentHandler,
     in_static_mode: bool,
     expectation: ContextManager[Any],
+    tiprack_lid_def: LabwareDefinition,
 ) -> None:
     """It should be able to retrieve a labware."""
     subject = RetrieveImpl(state_view=state_view, equipment=equipment)
@@ -59,11 +70,28 @@ async def test_retrieve(
     decoy.when(
         state_view.modules.get_flex_stacker_substate(module_id="flex-stacker-id")
     ).then_return(fs_module_substate)
+    decoy.when(state_view.labware.get("labware-id")).then_return(
+        LoadedLabware(
+            id="labware-id",
+            loadName="tiprack",
+            definitionUri=uri_from_details(namespace="a", load_name="b", version=1),
+            location=DeckSlotLocation(slotName=DeckSlotName.SLOT_3),
+            offsetId=None,
+            lid_id="lid-id",
+            displayName="Labware",
+        )
+    )
 
     decoy.when(state_view.labware.get_dimensions(labware_id="labware-id")).then_return(
         Dimensions(x=1, y=1, z=1)
     )
 
+    decoy.when(state_view.labware.get_definition("lid-id")).then_return(tiprack_lid_def)
+
+    decoy.when(
+        state_view.labware.get_labware_overlap_offsets(tiprack_lid_def, "tiprack")
+    ).then_return(OverlapOffset(x=0, y=0, z=14))
+
     decoy.when(
         equipment.get_module_hardware_api(FlexStackerId("flex-stacker-id"))
     ).then_return(fs_hardware)
@@ -72,7 +100,7 @@ async def test_retrieve(
         result = await subject.execute(data)
 
     if not in_static_mode:
-        decoy.verify(await fs_hardware.dispense_labware(labware_height=1), times=1)
+        decoy.verify(await fs_hardware.dispense_labware(labware_height=4), times=1)
 
         assert result == SuccessData(
             public=flex_stacker.RetrieveResult(labware_id="labware-id"),

api/tests/opentrons/protocol_engine/commands/flex_stacker/test_store.py

@@ -1,9 +1,10 @@
 """Test Flex Stacker store command implementation."""
-from decoy import Decoy
 import pytest
+from decoy import Decoy
 from contextlib import nullcontext as does_not_raise
 from typing import ContextManager, Any
 
+from opentrons.calibration_storage.helpers import uri_from_details
 from opentrons.hardware_control.modules import FlexStacker
 
 from opentrons.protocol_engine.state.update_types import (
@@ -22,8 +23,17 @@
 from opentrons.protocol_engine.commands import flex_stacker
 from opentrons.protocol_engine.commands.command import SuccessData
 from opentrons.protocol_engine.commands.flex_stacker.store import StoreImpl
-from opentrons.protocol_engine.types import Dimensions, OFF_DECK_LOCATION
+from opentrons.protocol_engine.types import (
+    DeckSlotLocation,
+    Dimensions,
+    OFF_DECK_LOCATION,
+    LoadedLabware,
+    OverlapOffset,
+)
 from opentrons.protocol_engine.errors import CannotPerformModuleAction
+from opentrons.types import DeckSlotName
+
+from opentrons_shared_data.labware.labware_definition import LabwareDefinition
 
 
 @pytest.mark.parametrize(
@@ -45,6 +55,7 @@ async def test_store(
     equipment: EquipmentHandler,
     in_static_mode: bool,
     expectation: ContextManager[Any],
+    tiprack_lid_def: LabwareDefinition,
 ) -> None:
     """It should be able to store a labware."""
     subject = StoreImpl(state_view=state_view, equipment=equipment)
@@ -64,11 +75,28 @@ async def test_store(
     decoy.when(
         state_view.labware.get_id_by_module(module_id="flex-stacker-id")
     ).then_return("labware-id")
+    decoy.when(state_view.labware.get("labware-id")).then_return(
+        LoadedLabware(
+            id="labware-id",
+            loadName="tiprack",
+            definitionUri=uri_from_details(namespace="a", load_name="b", version=1),
+            location=DeckSlotLocation(slotName=DeckSlotName.SLOT_3),
+            offsetId=None,
+            lid_id="lid-id",
+            displayName="Labware",
+        )
+    )
 
     decoy.when(state_view.labware.get_dimensions(labware_id="labware-id")).then_return(
         Dimensions(x=1, y=1, z=1)
     )
 
+    decoy.when(state_view.labware.get_definition("lid-id")).then_return(tiprack_lid_def)
+
+    decoy.when(
+        state_view.labware.get_labware_overlap_offsets(tiprack_lid_def, "tiprack")
+    ).then_return(OverlapOffset(x=0, y=0, z=14))
+
     decoy.when(
         equipment.get_module_hardware_api(FlexStackerId("flex-stacker-id"))
     ).then_return(fs_hardware)
@@ -77,7 +105,7 @@ async def test_store(
         result = await subject.execute(data)
 
     if not in_static_mode:
-        decoy.verify(await fs_hardware.store_labware(labware_height=1), times=1)
+        decoy.verify(await fs_hardware.store_labware(labware_height=4), times=1)
         assert result == SuccessData(
             public=flex_stacker.StoreResult(),
             state_update=StateUpdate(

api/tests/opentrons/protocol_engine/conftest.py

@@ -171,6 +171,14 @@ def magdeck_well_plate_def() -> LabwareDefinition:
     )
 
 
+@pytest.fixture(scope="session")
+def tiprack_lid_def() -> LabwareDefinition:
+    """Get the definition of the opentrons tiprack lid."""
+    return LabwareDefinition.model_validate(
+        load_definition("opentrons_flex_tiprack_lid", 1, schema=3)
+    )
+
+
 @pytest.fixture(scope="session")
 def tempdeck_v1_def() -> ModuleDefinition:
     """Get the definition of a V1 tempdeck."""

shared-data/deck/definitions/5/ot3_standard.json

@@ -1023,7 +1023,7 @@
       "mayMountTo": ["cutoutD3"],
       "displayName": "Flex Stacker With Waste Chute Adapter for 96 Channel Pipette or Gripper",
       "providesAddressableAreas": {
-        "cutoutD3": ["1ChannelWasteChute", "8ChannelWasteChute", "D4"]
+        "cutoutD3": ["1ChannelWasteChute", "8ChannelWasteChute", "flexStackerModuleV1D4"]
       },
       "fixtureGroup": {},
       "height": 124.5

shared-data/labware/definitions/3/opentrons_flex_tiprack_lid/1.json

@@ -43,37 +43,37 @@
     "default": {
       "x": 0,
       "y": 0,
-      "z": 8.193
+      "z": 14
     },
     "opentrons_flex_96_filtertiprack_200ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     },
     "opentrons_flex_96_filtertiprack_1000ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     },
     "opentrons_flex_96_tiprack_20ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     },
     "opentrons_flex_96_tiprack_50ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     },
     "opentrons_flex_96_tiprack_200ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     },
     "opentrons_flex_96_tiprack_1000ul": {
       "x": 0,
       "y": 0,
-      "z": 8.25
+      "z": 14
     }
   },
   "stackLimit": 1,
@@ -86,7 +86,7 @@
     "opentrons_flex_96_filertiprack_1000ul"
   ],
   "gripForce": 15,
-  "gripHeightFromLabwareBottom": 8,
+  "gripHeightFromLabwareBottom": 4,
   "gripperOffsets": {
     "default": {
       "pickUpOffset": {

shared-data/python/opentrons_shared_data/labware/__init__.py

@@ -12,9 +12,9 @@
 Schema = NewType("Schema", Dict[str, Any])
 
 
-def load_definition(loadname: str, version: int) -> "LabwareDefinition":
+def load_definition(loadname: str, version: int, schema: int = 2) -> "LabwareDefinition":
     return json.loads(
-        load_shared_data(f"labware/definitions/2/{loadname}/{version}.json")
+        load_shared_data(f"labware/definitions/{schema}/{loadname}/{version}.json")
     )