Great post...
I also deliver insulin with my Cozmo when the cartridge is "empty". I have used the temporary basal rate also, but you can even give a bolus!! If you go into "Load" and "Fill Cannula", you can even give a bolus when the Cozmo tells you that there is no insulin left. I find myself in this situation all too often... so I too should be more prepared, but it's good to know what to do in a jam!
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I had a similar problem this morning when I got to the office. I needed to change out my set this morning, but didn't have time before leaving the house, so I grabbed my kit and a new infusion set and dropped them into my backpack. When I went to change out the set, I discovered that I hadn't replaced the infusion set I used the last time I was away from home. Luckily I didn't have any problems with this set going in properly, but sometimes I've found that the needle has bent or that the tubing has crimped when I removed the needle. In times like these it really helps to have that spare set on hand. Maybe I should just bring a set into the office and lock it in the filing cabinet so I don't have to worry about my replacement set not working properly.
I have been pumping for the last 22 months and I have experienced both of your situations. What I do now is, I have a small refrigerator under my desk and I keep a bottle of insulin in it for emergencies as well as 3 sets of tubing in my desk drawer. JMIL