R2 is fully working except for when running on carpet.

If I raise up the third leg using washers - he runs fine on carpet in manual mode, however he no longer works in patrol mode - the raised front sensor is now too far off the ground & makes R2 think he's over a ledge so sticks him permanently in reverse.

so basically.......

No washers - works hard floor in manual & patrol mode / will not function on carpet
Washer & spring washer - works hard floor in manual, patrol mode just reverses / only just functions on carpet in both manual & patrol mode (rocks whilst moving)
Spare Nut - works hard floor in manual, patrol mode just reverses / functions perfectly on carpet in manual, patrol mode just reverses

So as it stands if I ever want him to work on carpet - I can never use patrol mode.

Anyone have any ideas?

@coldsweat

Are you able to put a plastic spacer under the sensor pcb to lower it perhaps? (so you raise the foot with the extra washers on the caster-wheel and at the same time are lowering the foot sensor)

I wonder about trying to measure the distance the sensor needs?
if you could find a thin spacer for the wheel that gave enough clearance but kept the sensor in range ?

another idea might be the angle the sensor is at ? is it facing straight to the floor when the foot is raised or is there an angle that might add a small distance factor ?

just a couple of millimeters might make a big difference in how it works.

also the angle, if the sensor it "looking" for the light from the led and it reflects at an angle where it can't see it...

just a few ideas on what to play with and look at.