Task-Error Residual Learning for Real-Robot Five-Ball Juggling
Authors: Kai Ploeger, Jan Peters
Organizations: Technical University of Darmstadt, Germany · German Research Center for AI (DFKI), Germany · Hessian Center for Artificial Intelligence (hessian.AI), Germany
Abstract
For residual learning that refines existing behavior, sample efficiency depends on two things: how much information each rollout returns, and how efficiently the learner uses that information. Reinforcement learning's standard scalar reward carries far less information than the directional task error that defines the task. Random exploration further discards whatever information each rollout returns. Through residual learning with directional task-error supervision and a task error model that drives sample selection, we achieve stable three-, four-, and five-ball juggling on anthropomorphic Barrett WAM arms. Despite planning and controlling through a simple, idealized stack, the system converges from the second attempt. The first attempt drops, after which task error decreases monotonically without further failures. In comparison, five-ball juggling typically takes humans years of practice. We compare residual learners across two ternary axes, the directional information in the learning feedback and the commitment of the analytic prior, spanning Newton-style Jacobian updates, Composite Bayesian Optimization, and stochastic search methods. Both axes prove necessary: neither directional feedback nor an informative prior suffices alone, and the simplest method that combines them, a fixed-Jacobian Newton update, is the most reliable. The learned residual tolerates substantial prior misalignment and degraded joint tracking, affecting mainly convergence speed. The bottleneck for residual learning on real robots is therefore the information content of the supervision signal and how the learner uses it, not the accuracy of the surrounding stack. Video documentation of all experiments is available at https://kai-ploeger.com/residual-juggling.
Dynamic object exchange between humans and robots remains a challenging problem due to uncertainty in perception, timing, and contact-rich interaction. Human-robot juggling represents a particularly demanding instance of this problem, requiring precise real-time coordination, predictive motion planning with feedback control, and robustness to variability in human motion. Enabling such skills is of interest for advancing physical human-robot interaction and shared autonomy. We present a real-time planning and control architecture for human-robot partner juggling that enables a robot to reliably catch and throw balls in synchronized multi-ball patterns with a human partner. The system integrates predictive ball tracking, adaptive online trajectory optimization using a multiple-shooting formulation, and a state-machine-based coordination logic to enable synchronized multi-ball human-robot partner juggling. In a user study with 8 participants of varying juggling skill from beginner to expert, we demonstrate that our system can achieve three-ball cascades shared between the robot and the human. All participants exceeded previously reported best-case results within a 10-minute test session, with one participant extending the previous record for shared three-ball cascade juggling fivefold to 20 consecutive robot catches, and another participant achieving a 100% success rate with 40 consecutive catches in a single-ball catch-and-return setting. Video documentation can be found at https://kai-ploeger.com/partner-juggling
Jonathan Rainer Lippert, Kai Ploeger, Abir Chowdhury +3
Non-prehensile object manipulation skills are important for real-world robot interactions, enabling highly dynamic tasks such as balancing a glass on a tray or the controlled sliding of items on a table. Among such tasks, those characterised by high-speed manipulation requirements and general sensitivity of the resulting hybrid dynamics are particularly hard to accomplish. Within these, juggling can be seen as a highly challenging maneuver to be solved. The key to robotic juggling is achieving dynamic stabilisation of an underactuated object. Since the object does not possess the ability of self-correction, its stability is entirely dependent on the forces applied to it. This creates a system that is sensitive to control inputs, where timing is critical to continuously counteract deviations and maintain the desired behavior. We develop a systematic method to control a 7-degree-of-freedom manipulator performing non-prehensile ball juggling with a tool. Our primary contribution is a model-based framework for generating juggling trajectories and stabilizing a periodic juggling motion for this hybrid system. The framework incorporates a two-stage optimal control approach to compute the underlying feasible motion patterns required for stable juggling. Offline-computed trajectories are then organised to enable real-time error correction without solving optimal control problems online. We demonstrate the effectiveness of the resulting controller by first evaluating its performance in a simulation environment and performing an experiment using a Franka Emika Panda robot.
Joel Ramadani, Vasilije Rakčević, Riddhiman Laha +4
Safe control of humanoid robots remains challenging due to their high-dimensional dynamics, contact-rich interactions, and sensitivity to disturbances. Although reinforcement learning has enabled effective locomotion and motion tracking, learned policies can still generate unsafe actions that lead to instability or falls. In this work, we propose residual reinforcement learning as an implicit safety-filtering mechanism for safe humanoid control. Instead of relying on a single nominal policy to simultaneously balance performance, safety, and robustness, we decouple performance and safety. The nominal policy focuses solely on task performance, while a residual policy learns safety corrections. This decoupling leads to a better performance--safety Pareto trade-off and avoids the need for careful tuning of multiple competing reward terms within a single policy training. We show that the residual policy can act as an implicit safety filter.