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I'm going to add another answer here, to give another possible cause of this problem in case people come looking.

I had this error when adding vision to MoveIt. I was streaming in 20 point clouds per second, and publishing 20 /joint_state messages per second also. My hunch is that MoveIt is using the same pool of asynchronous threads to process both these messages. I suspect that because I was sending so many point clouds, there were occasions where all threads were being used to process point clouds, and none were processing the /joint_state callbacks within the required 1 second.

I throttled the point cloud back to once per second and everything is back to normal.

I'm going to add another answer here, to give another possible cause of this problem in case people come looking.

I had this error when adding vision to MoveIt. I was streaming in 20 point clouds per second, and publishing 20 /joint_state joint state messages per second also. My hunch is that MoveIt is using the same pool of asynchronous threads to process both these messages. I suspect that because I was sending so many point clouds, there were occasions where all threads were being used to process point clouds, and none were processing the /joint_state joint state callbacks within the required 1 second.

I throttled the point cloud back to once per second and everything is back to normal.