Controller Manager recovery from invalid URDF errors (backport #2775)

[mergify]

Goal:

Update the Controller Manager to handle errors when the ResourceManager fails to initialize due to an invalid URDF or faulty hardware plugin.

Behavior:

• Catch exceptions caused by parsing invalid URDFs during initialization
• Log error messages
• Reset the resource_manager_ pointer to a minimal, safe state.
• Continue waiting for a valid robot_description to be published

Observations:

The Controller Manager now no longer crashes on invalid URDFs. Instead, it safely recovers by initializing the resource_manager_ pointer to a minimal state, allowing the controller manager to continue operating and respond to future valid robot descriptions.

Testing:
Unit tests were created with multiple invalid URDF scenarios. All tests passed successfully. Testing can be done by executing:
./build/controller_manager/test_controller_manager_with_resource_manager

---

This is an automatic backport of pull request #2775 done by [Mergify](https://mergify.com).

[mergify]

Cherry-pick of 189f705 has failed:

On branch mergify/bp/jazzy/pr-2775
Your branch is up to date with 'origin/jazzy'.

You are currently cherry-picking commit 189f705.
  (fix conflicts and run "git cherry-pick --continue")
  (use "git cherry-pick --skip" to skip this patch)
  (use "git cherry-pick --abort" to cancel the cherry-pick operation)

Changes to be committed:
	modified:   controller_manager/CMakeLists.txt
	modified:   controller_manager/include/controller_manager/controller_manager.hpp
	modified:   controller_manager/test/controller_manager_test_common.hpp
	modified:   controller_manager/test/test_controller_manager_hardware_error_handling.cpp
	modified:   controller_manager/test/test_controller_manager_srvs.cpp
	modified:   controller_manager/test/test_controller_manager_urdf_passing.cpp
	modified:   controller_manager/test/test_controller_manager_with_namespace.cpp
	new file:   controller_manager/test/test_controller_manager_with_resource_manager.cpp
	new file:   controller_manager/test/test_controller_manager_with_resource_manager.hpp
	modified:   controller_manager/test/test_controllers_chaining_with_controller_manager.cpp
	modified:   controller_manager/test/test_hardware_spawner.cpp
	modified:   controller_manager/test/test_spawner_unspawner.cpp
	modified:   ros2_control_test_assets/include/ros2_control_test_assets/descriptions.hpp

Unmerged paths:
  (use "git add <file>..." to mark resolution)
	both modified:   controller_manager/src/controller_manager.cpp
	both modified:   hardware_interface/src/resource_manager.cpp

To fix up this pull request, you can check it out locally. See documentation: https://docs.github.com/en/pull-requests/collaborating-with-pull-requests/reviewing-changes-in-pull-requests/checking-out-pull-requests-locally

[VitezGabriela]

I checked against current jazzy: merging this branch into jazzy is a clean merge with 0 conflicts. Label seems to be stale.

[VitezGabriela]

There is a failing test_controller_manager_with_resource_manager which is caused by a pre-existing jazzy bug in ResourceManager::load_and_initialize_components() (the init flag was set before the URDF parse, so an invalid URDF was reported as initialized).

I've opened a fix in #3443.. Could a maintainer please merge it?

[codecov]

Codecov Report

❌ Patch coverage is 87.50000% with 17 lines in your changes missing coverage. Please review.
✅ Project coverage is 89.40%. Comparing base (0194fdd) to head (dba1be7).

Files with missing lines	Patch %	Lines
controller_manager/src/controller_manager.cpp	85.24%	4 Missing and 5 partials ⚠️
controller_manager/test/test_hardware_spawner.cpp	0.00%	2 Missing and 1 partial ⚠️
controller_manager/test/test_spawner_unspawner.cpp	0.00%	2 Missing and 1 partial ⚠️
.../test_controller_manager_with_resource_manager.cpp	96.00%	0 Missing and 2 partials ⚠️

Additional details and impacted files

@@            Coverage Diff             @@
##            jazzy    #3394      +/-   ##
==========================================
- Coverage   89.44%   89.40%   -0.05%     
==========================================
  Files         161      162       +1     
  Lines       20567    20637      +70     
  Branches     1630     1639       +9     
==========================================
+ Hits        18397    18451      +54     
- Misses       1500     1508       +8     
- Partials      670      678       +8     

Flag	Coverage Δ
unittests	89.40% <87.50%> (-0.05%)	⬇️

Flags with carried forward coverage won't be shown. Click here to find out more.

Files with missing lines	Coverage Δ
...interface/include/controller_interface/helpers.hpp	61.53% <ø> (ø)
.../include/controller_manager/controller_manager.hpp	97.29% <ø> (ø)
...er_manager/test/controller_manager_test_common.hpp	89.04% <100.00%> (+0.88%)	⬆️
...est_controller_manager_hardware_error_handling.cpp	100.00% <100.00%> (ø)
...ller_manager/test/test_controller_manager_srvs.cpp	99.37% <100.00%> (-0.01%)	⬇️
...ager/test/test_controller_manager_urdf_passing.cpp	100.00% <100.00%> (ø)
...er/test/test_controller_manager_with_namespace.cpp	100.00% <100.00%> (ø)
...t_controllers_chaining_with_controller_manager.cpp	99.01% <100.00%> (-0.01%)	⬇️
hardware_interface/src/resource_manager.cpp	81.00% <100.00%> (-0.50%)	⬇️
.../test_controller_manager_with_resource_manager.cpp	96.00% <96.00%> (ø)
... and 3 more

🚀 New features to boost your workflow:

• ❄️ Test Analytics: Detect flaky tests, report on failures, and find test suite problems.

[destogl]

Thanks for the following up!

[mergify]

Tick the box to add this pull request to the merge queue (same as @mergifyio queue).

• Queue this pull request

[christophfroehlich]

This broke gz_ros2_control, see #3401

Let us fix this first before we merge this PR into jazzy.

[saikishor]

This broke gz_ros2_control, see #3401

Let us fix this first before we merge this PR into jazzy.

We should wait for atleast a release or do we want to backport this to Jazzy?

[christophfroehlich]

Needs #3459

[mergify]

This pull request is in conflict. Could you fix it @bmagyar @destogl @christophfroehlich @saikishor?