Health-Conditioned Vision-Language-Action Models for Malfunction-Aware Robot Control

Deploying Vision-Language-Action (VLA) models in real robotic systems requires robustness not only to semantic and perceptual variations, but also to embodiment-side faults that change how actions are physically realized. Real robots can experience joint-level changes caused by actuator degradation, hardware faults, safety limits, collision damage, or wear-induced friction. These faults are critical because they alter the action-to-motion interface of a policy, disrupting the learned closed-loop relationship between commanded actions, realized motion, and subsequent observations. In this work, we study realistic joint-level physical faults and show that VLA models are vulnerable when predicted actions are executed through a perturbed robot body. Our analysis reveals joint-dependent effects, with heterogeneous degradation in task success across affected joints. We also show that performance drops cannot be attributed solely to physical infeasibility, since feasible faults such as increased joint friction can still substantially reduce success rates and induce closed-loop execution mismatch. Motivated by these findings, we propose Joint-level Physical-fault Aware Residual Calibrator (J-PARC), a lightweight residual calibration framework built on top of a frozen VLA policy. J-PARC infers a latent joint-fault regime from recent joint dynamics and conditions a shared residual calibrator on this regime, enabling adaptive action correction across faulty joints. Experiments show that J-PARC improves robustness under joint-level faults while preserving fault-free environment performance.

Vision-language-action (VLA) models have emerged as generalist robotic controllers capable of mapping visual observations and natural language instructions to continuous action sequences. However, VLAs provide no calibrated measure of confidence in their action predictions, thus limiting their reliability in real-world settings where uncertainty and failures must be anticipated. To address this problem we introduce ReconVLA, a reliable conformal model that produces uncertainty-guided and failure-aware control signals. Concretely, our approach applies conformal prediction directly to the action token outputs of pretrained VLA policies, yielding calibrated uncertainty estimates that correlate with execution quality and task success. Furthermore, we extend conformal prediction to the robot state space to detect outliers or unsafe states before failures occur, providing a simple yet effective failure detection mechanism that complements the action-level uncertainty. We evaluate ReconVLA in both simulation and real robot experiments across diverse manipulation tasks. Our results show that conformalized action predictions consistently improve failure anticipation, reduce catastrophic errors, and provide a calibrated measure of confidence without retraining or modifying the underlying VLA.

Vision-language-action (VLA) models provide a promising paradigm for scalable robotic manipulation, yet their reliance on success-only behavioral cloning leaves them brittle; lacking corrective training signals, minor execution errors rapidly compound into unrecoverable, out-of-distribution failures. To address this limitation, we propose Adaptive Failure-Informed Learning (AFIL), an end-to-end framework that leverages failure trajectories as adaptive negative guidance for diffusion- and flow-based VLA policies. AFIL uses a pretrained VLA to generate failure rollouts online, avoiding the need for handcrafted failure-mode design or human-in-the-loop recovery. It then jointly trains Dual Action Generators (DAGs) for successful and failed behaviors while sharing a common vision-language backbone, enabling efficient failure-aware policy learning with limited parameter overhead. During sampling, the failure generator adaptively steers action generation away from failure-prone regions and toward more reliable success modes, with guidance strength determined by the per-diffusion-step distance between success and failure distributions. Experiments across in-domain and out-of-domain robotic manipulation tasks, covering both short- and long-horizon settings, show that AFIL consistently improves task success rates and robustness over existing VLA baselines, demonstrating its effectiveness, efficiency, and generality.