Behavioral Cloning for Robotic Connector Assembly: An Empirical Study

Reliable insertion of industrial connectors remains a central challenge in robotics, requiring sub-millimeter precision under uncertainty and often without full visual access. Vision-based approaches struggle with occlusion and limited generalization, while learning-based policies frequently fail to transfer to unseen geometries. To address these limitations, we leverage tactile sensing, which captures local surface geometry at the point of contact and thus provides reliable information even under occlusion and across novel connector shapes. Building on this capability, we present Touch2Insert, a tactile-based framework for arbitrary peg insertion. Our method reconstructs cross-sectional geometry from high-resolution tactile images and estimates the relative pose of the hole with respect to the peg in a zero-shot manner. By aligning reconstructed shapes through registration, the framework enables insertion from a single contact without task-specific training. To evaluate its performance, we conducted experiments with three diverse connectors in both simulation and real-robot settings. The results indicate that Touch2Insert achieved sub-millimeter pose estimation accuracy for all connectors in simulation, and attained an average success rate of 86.7% on the real robot, thereby confirming the robustness and generalizability of tactile sensing for real-world robotic connector insertion.

Contact-rich precision insertion is a key manipulation skill in robotic assembly. Tight clearances make insertion more sensitive to alignment errors and prone to collisions and jamming, while variations in geometry and clearance across parts further complicate policy reuse. We present a reinforcement learning framework that trains insertion policies entirely in simulation for direct deployment without real-world demonstrations or policy fine-tuning. By combining target poses with compact three-dimensional fingertip force feedback, the policy learns to search for alignment and correct its motion despite errors in the estimated hole position. A decoupled gated reward coordinates alignment and insertion. Force-signal smoothing and state-independent standard deviations stabilize the learning process. The resulting policies perform real-world insertion across multiple hole geometries with a minimum nominal clearance of 0.02 mm and improve success while reducing peak contact forces under hole-position errors. Cross-clearance and cross-geometry evaluations further confirm policy generalization. The system achieved the first perfect score of 20/20 on ManipulationNet's peg-in-hole benchmark under its Human-in-the-Loop protocol, with fully autonomous insertion motions. A single policy trained only on a simulated hexagonal insertion task achieved an overall success rate of 95.0% across eight unseen real-world insertion tasks. These results show that learning entirely in simulation can yield precision insertion skills that can be deployed directly and reused across real-world tasks. The project website (https://mzhsoul.github.io/InsertAnything/) provides open-source simulation and real-robot experiment scripts, assets, and trained checkpoints.

Robotic assembly in high-mixture settings requires adaptable systems that can handle diverse parts, yet current approaches typically rely on policies specialized to each insertion task. Although this can reach high success rates, it makes the process of deploying systems for new problems tedious and time consuming. We present a framework for generalizable insertion using world models that combine robot proprioceptive information with raw visual observations captured by a wrist-mounted camera. Our model-based approach trains a single world model on up to 90 insertion tasks with geometrically diverse parts, achieving 56% zero-shot success on unseen objects with unknown geometry compared to just 7% with a model-free baseline. Importantly, performance improves as more objects are included in the training dataset, demonstrating strong scalability. Lastly, finetuning the generalist model on held-out objects significantly enhances data-efficiency compared to training from scratch and, in some cases, achieves better asymptotic performance. To our knowledge, this is the first system capable of assembling unseen objects in an entirely data-driven manner, and thus represents a significant step toward scalable, generalizable robotic assembly systems.