First news: this is not a flaky problem and does not related to closed #1585 ticket. The problem is a test false-positive case uncovered by ee719c9 commit. In this commit the planner tolerance was decreased from 2.0 -> to 0.5.

Using test_planner_costmaps_node test as an example of what's happening in CI.
When tolerance was 2.0, the planner produced path as follows:

   point #0 with x: 1 y: 1
   point #1 with x: 1.7 y: 1.7
   point #2 with x: 2.05 y: 2.05
   point #3 with x: 2.4 y: 2.4
   point #4 with x: 2.76 y: 2.76
   point #5 with x: 3.11 y: 3.11
   point #6 with x: 3.46 y: 3.46
   point #7 with x: 3.82 y: 3.82
   point #8 with x: 4.17 y: 4.17
   point #9 with x: 4.53 y: 4.53
   point #10 with x: 4.88 y: 4.88
   point #11 with x: 5.23 y: 5.23
   point #12 with x: 5.59 y: 5.59
   point #13 with x: 5.94 y: 5.94
   point #14 with x: 6.29 y: 6.29
   point #15 with x: 6.65 y: 6.65
   point #16 with x: 7 y: 7
   point #17 with x: 8 y: 8
   point #18 with x: 8 y: 8

After decreasing the tolerance to 0.5 the planner became to produce the another path:

   point #0 with x: 1 y: 1
   point #1 with x: 1.7 y: 1.7
   point #2 with x: 2.05 y: 2.05
   point #3 with x: 2.4 y: 2.4
   point #4 with x: 2.76 y: 2.76
   point #5 with x: 3.11 y: 3.11
   point #6 with x: 3.46 y: 3.46
   point #7 with x: 3.82 y: 3.82
   point #8 with x: 4.17 y: 4.17
   point #9 with x: 4.53 y: 4.53
   point #10 with x: 4.88 y: 4.88
   point #11 with x: 5.23 y: 5.23
   point #12 with x: 5.59 y: 5.59
   point #13 with x: 5.94 y: 5.94
   point #14 with x: 6.29 y: 6.29
   point #15 with x: 6.65 y: 6.65
   point #16 with x: 7 y: 7
   point #17 with x: 7.5 y: 7.5  <- not equal to x: 8.0 y: 8.0

Which causes messages like:

[WARN] [1589538666.451800381] [PlannerTester]: Path deviates from requested start and end points

and failures of testcases.

I think, produced paths in both cases are correct, since the goal places within its tolerance <=0.5 but according to PlannerTester::isWithinTolerance() logic goal should be strictly equal to (x: 8.0 y: 8.0):

 if (
    path_start.pose.position.x == robot_position.x &&
    path_start.pose.position.y == robot_position.y &&
    path_end.pose.position.x == goal.pose.position.x &&
    path_end.pose.position.y == goal.pose.position.y)
  {
    RCLCPP_DEBUG(this->get_logger(), "Path has correct start and end points");
    return true;
  }

It looks like the conditions in PlannerTester::isWithinTolerance() should be changed in order to taking deviationTolerance into account:

    path_start.pose.position.x == robot_position.x &&
    path_start.pose.position.y == robot_position.y &&
    path_end.pose.position.x <= goal.pose.position.x + deviationTolerance &&
    path_end.pose.position.x >= goal.pose.position.x - deviationTolerance &&
    path_end.pose.position.y <= goal.pose.position.y + deviationTolerance &&
    path_end.pose.position.y >= goal.pose.position.y - deviationTolerance)

Flaky Planner Tests (part 3) #1733

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