Force-Aware Residual DAgger via Trajectory Editing for Precision Insertion with Impedance Control

In robotic insertion under uncertain contact, the axial force limit and the appropriate controller gain vary across tasks. As a result, a single fixed gain is unlikely to remain suitable across different task conditions, making conventional impedance controllers reliant on manual retuning. To eliminate manual retuning, we propose Constraint-Grounded Reinforcement Learning (CG-RL), a variable impedance framework for online gain adaptation. Conditioned on the force limit and contact feedback, the policy outputs a residual motion, an insertion rate, and a requested gain. The controller projects this gain into the admissible range without exposing the range itself to the policy. This separation allows a single policy to operate under different force limits without retraining or manual retuning. We evaluate CG-RL on simulated oblique insertion across five training seeds. CG-RL achieves an $85.8\pm7.7\%$ (mean $\pm$ SD) success rate of insertions without violating the force limit, while keeping the applied gain within the admissible range. As a comparison, a fixed-gain baseline using the midpoint gain achieves a success rate of $50.1\%$. The policy adapts its insertion rate continuously to the specified force limit and further generalizes to more permissive force limits above the training range. In contrast, the same actor without force-limit input does not exhibit this adaptation. The applied gain is guaranteed to remain within the admissible range, while force-limit satisfaction is validated empirically rather than guaranteed formally.

Contact-rich manipulation requires robots to regulate force against surfaces whose geometry deviates unpredictably from training conditions. Trajectory-based imitation learning, which reproduces observable outputs, breaks down under such shifts. We propose Impedance Cloning, which instead imitates the biomechanical priors that generate motion -- the stiffness and equilibrium point -- and thereby passively absorbs contact uncertainty. Because these parameters encode intent rather than outcome, they generalize across surface geometries where trajectory reproduction does not. We extract them from bilateral teleoperation demonstrations via a particle filter without force/torque sensors and evaluate the framework on two CRANE-X7 manipulators. In a wiping task with joint-space actions, the trajectory-based baseline loses contact below -6 cm, whereas the proposed method maintains a consistent 4-5 N contact force above -6 cm, with a gradual decrease below; with Cartesian-space actions, its force-height slope over 0 to +8 cm is 0.13 +/- 0.03 N/cm, versus 0.34-0.83 N/cm for fixed-impedance baselines. In a pick-and-place task with 10 diverse cups (100 trials), the proposed method succeeds in 84 trials, outperforming the fixed-impedance baseline (74/100) and performing comparably to a variable impedance control baseline (82/100) with one demonstration instead of ten. In a grasping task, the representation reduces torque tracking error with both ILBiT and Mamba backbones, confirming its generality across architectures.

Generalizable contact-rich manipulation requires robots to preserve intended task behavior while adapting its physical realization to changing contact conditions. However, interaction forces can vary substantially with small changes in surface geometry, orientation, and friction, making policies trained directly on raw force measurements difficult to transfer beyond demonstrated conditions. We introduce FACE, a contact-factorized imitation learning framework that separates intended task behavior from environment-dependent contact factors. Our representation expresses interaction forces in normalized, contact-relative coordinates, while a learned contact-normal estimator and an online friction estimator infer the local contact normal and effective friction scale. Together, these estimators enable force observations to be encoded and policy outputs to be decoded into physical motion and force commands during execution. In this way, FACE adapts execution to current contact conditions while preserving the intended task behavior, without updating the policy parameters. We evaluate FACE on real-robot contact-rich manipulation under unseen variations in surface properties and geometry, demonstrating robust generalization across contact conditions through controlled comparisons with variants that adapt prior approaches to our setting. Videos and additional materials can be found on the project page: https://rcilab.khu.ac.kr/face.