Stiffness Copilot: An Impedance Policy for Contact-Rich Teleoperation

Contact-rich manipulation requires robots to balance accurate motion tracking with compliant interaction, yet most visual-action policies leave compliance fixed at the controller level. We present Imp-ACT, a methodologically grounded and practical approach to incorporating direction-dependent Cartesian stiffness modulation directly into demonstration collection, without manual stiffness selection or offline target reconstruction. During teleoperation, a self-tuning impedance controller adapts stiffness along the instantaneous direction of motion while maintaining compliance in orthogonal directions. The adapted stiffness is applied and recorded alongside visual observations and motion commands, capturing motion and compliance under the same dynamics. We implement this pipeline using Action Chunking with Transformer (ACT) to predict end-effector pose, gripper action, and motion-direction stiffness from visual, proprioceptive, and wrench observations. The performance of Imp-ACT is evaluated on wiping and plug insertion using both success rate and quantitative measures of contact behavior. Compared with fixed low- and high-stiffness baselines, Imp-ACT achieves comparable or higher success while maintaining low interaction forces. In wiping, it reduces contact-force vibration by approximately $29\times$ relative to the compliant baseline and $180\times$ relative to the stiff baseline. In plug insertion, it reduces forces orthogonal to the insertion direction by $43\%$ relative to the better fixed-stiffness baseline. These results highlight the benefit of maintaining sufficient stiffness along the direction needed for task execution while preserving compliance in other directions to limit contact forces and accommodate environmental constraints.

Manipulation tasks such as unscrewing a cap or sliding a part in contact with a surface require imposing force along a high-friction direction: the robot must overcome a resistance rather than yield to it. Generative visuomotor policies predict the motion for such tasks but not the authority needed to realize it, and that authority is bounded by the impedance controller beneath them: when the resistance exceeds what a compliant controller can exert under a bounded tracking error, the task is unattainable however accurate the prediction is. The required amount cannot be anticipated either, since it depends on a contact state the observation does not reveal. In this paper, we propose a residual stiffening layer placed underneath an unmodified policy. Resistance is recognized, without force sensing, from the mismatch between the motion the policy commands and the motion the robot realizes, and a four-mode supervisor raises the stiffness along a single direction read off the policy's own action chunk, retains it while the task progresses and releases it afterwards. The layer needs no compliance labels, no retraining and no re-collected demonstrations. On two real tasks, unscrewing a bottle cap and pushing a T-nut along a T-slot groove against non-homogeneous friction, evaluated at six resistance levels of which two were withheld from the demonstrations, the layer raises the success rate from 52% to 90% while producing 61% less peak off-axis force than a uniformly stiff controller at the same resistance.

Learning-based manipulation policies usually predict robot actions from sensory observations and leave their execution to a separate low-level controller. In rigid contact, this separation can be problematic: the same motion to a virtual target or compliant motion command can lead to unstable contact, tracking error, excessive loading, or tool damage, depending on the low-level controller. In this paper, we propose a Unified Robot Control-Policy Framework (URF), which connects compliant action prediction with unified impedance-admittance control. Given multimodal observations, URF predicts a virtual target, a stiffness matrix, and an impedance-admittance switch ratio. The switch ratio determines when the controller should behave more like admittance control for accurate motion tracking and when it should move toward impedance control for safer rigid contact. Because demonstration data do not provide ground-truth environment stiffness, we construct switch-ratio labels from measured contact forces and use them to supervise controller-mode prediction. Across box-flipping and line-pressing tasks, URF achieves higher task success rates while reducing failure modes observed with admittance-only execution, including rapid force buildup, large force oscillations, tool breakage, and robot safety stops. These results suggest that contact-aware policies benefit from predicting not only compliant actions but also the controller behavior used to execute them. Project page: https://jiyou384.github.io/urf_project_page/