Protective Stop on Move Until Tool Contact

I have a program that has been working well for a while now, and twice when I have turned the robot on it fails.

The program moves to a position (given by a camera) and then searches down until tool contact is made. Normally it stops and then makes a few more moves and picks up the item.

Twice now we have powered up the robot and started the program, and it has got to this point in the code, moved to the position given by the camera and started moving down until it hits the parts.. and then continued until a protective stop happens. Both times starting the program from the start again resulted in the same error.

Restarting the whole robot and the problem goes away. I haven’t been there myself either time the robot was started with the problem, so I can’t be sure there wasn’t something strange about how it was started… but I can’t figure it out.

Any suggestions? I am a bit confused.

try using zero_ftsensor() while stationary just before moving down

Thanks, I’ll add that in and see if it happens again… although I didn’t think that the move until tool contact actually used the sensor (just tracked robot position to detect the contact).