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We have been trying to debug this issue since the past 2 days. With no clear reason for this problem, we decided to try solving the IK of robot of the same configuration with a simple URDF file. So we wrote a urdf by hand, with the same joint and link config as our robot. The URDF we used earlier was generated from our original CAD model using the Solidworks URDF Converter plugin.
With this simple URDF, we did the same process as mentioned above. From this new MoveIt config, the plans were working significantly better. With the earlier urdf, hardly 1 out of 10 plans would work and even simple plans where only 1 motor had to move were failing. But with this new URDF model, many plans are working realli good! Even with the basic KDL solver with OMPL. And this is the same 5 dof configuration we had before. Our guess is that the solidworks urdf exporter plugin, which is severely dated, might be causing the issues in the planning. But we are still figuring out the actual, fundamental cause for this issue.
As far as solving the above problem is concerned, building a URDF by hand solves this problem for us. Even the IKfast library generates an analytical cpp solution.
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