With Bob's Logistics the deploy station spawns a couple more bots than fit in the robochests. It's around 2 bots if the deploy station is adjacent to the robochest with robot speed 28 researched, but when the deployment station is far it's more than that. Also when there are bots already delivering something (like placing a huge blueprint) which frees up a couple of slots leaving nowhere for the original bots to go. I think this is because the deploy station checks the amount of free inventory space in roboports instead of free inventory space in roboports minus robots in the network which are airborne
EDIT: I think a solution could be either to deploy if roboport space minus airborne robots is more than zero
or maybe if the robot is still standing over the deployment station then put it back? but in that case if the new robots were faster than the robots who are doing something else there would still be robots without a place to go.
PS I misclicked the edit button so it's a quote now, shoot