Beyond Heuristics: A Standardized Real2Sim Pipeline for Physical Human Robot Interaction in Human-in-the-Loop Simulation
Authors: Chengyuan Yang, Yifan Wang, Chun Kwang Tan, Sherwin Stephen Chan, Youlong Wang, Xiaoyue Yan, Lei Li, Wei Tech Ang
Abstract
The aging global population drives demand for assistive robots, yet the safety risks and costs of physical testing make Human-in-the-Loop (HITL) simulation an attractive alternative. Its fidelity for coupled systems, however, is limited by interaction models whose impedance parameters are tuned heuristically rather than identified from data. We present a Real2Sim pipeline that identifies the coupled Physical Human-Robot Interaction (pHRI) dynamics of a pelvis--strap interface on an overground mobile balance assistant. The interface is modeled as a 6-DoF viscoelastic mechanism whose 12 directional stiffness and damping parameters are identified per subject via Covariance Matrix Adaptation Evolution Strategy (CMA-ES), using the user's ``Safe & Comfortable'' feedback as a reproducible operating point that resolves harness-tightness ambiguity across anthropometrics. An intraclass-correlation analysis over a five-subject cohort separates shareable from subject-specific parameters, yielding a set of prior parameters derived from the existing data. Deploying this prior configures a previously unseen subject by refining only 5 of the 12 parameters. The calibrated model then reproduces the real interaction envelope and induces biomechanically accurate gait adaptations in the Human Digital Twin (HDT). Overly compliant and overly stiff settings, by contrast, fail as extreme settings, confirming a correct operating point that no heuristic tuning procedure can reliably select. The pipeline thus improves HITL simulation fidelity and supports the Human Digital Twin as a predictive tool for pre-clinical verification of personalized controllers.
Physical human-robot interaction requires yielding transiently to contact yet recovering the commanded reference under sustained load. Finite-stiffness impedance control retains a static deflection there, while predictive alternatives typically optimize a nonlinear robot or impedance model online. Operational-space cancellation instead exposes a translational error double integrator with a fixed transition matrix and a configuration-scheduled input map, making interaction a predictive quantity rather than a property re-derived per configuration. We build on it a compact offset-free interaction-error MPC for torque-controlled manipulators: a force-domain random-walk state estimates persistent interaction and model error, and a 30-variable convex QP maps the correction through the current task inertia while constraining the applied joint torque. Conditional results establish impedance equivalence of the unconstrained passive feedback, offset-free regulation at feasible frozen configurations, and quadratic stabilizability of the scheduled backbone. In a 1kHz MuJoCo simulation of a 7-DOF Franka FR3, the estimator cuts steady-state error under a repeated 15N step from 2.77mm to 0.042mm when added to the otherwise identical 100Hz MPC. A stiffness-and-damping-calibrated impedance baseline attains 2.59mm but briefly saturates and needs 3.3x the peak positive joint power. Adding ideal measured-force cancellation to that baseline gives 1.39mm, so constant-load rejection is not unique to MPC; the sensorless controller still reaches 0.042mm in the moving task, a 65x reduction without force sensing and without the baseline's saturation or power cost. Demonstrated in simulation under a shared actuator budget, the contribution is an efficient operational-space realization complementing rather than replacing broader interaction-control architectures.
Real-to-sim conversion for robotic interaction with objects remains labor-intensive because it requires more than visual reconstruction: a streamlined real2sim process must recover scene geometries and object states, infer physical parameters, and assemble actors, objects, cameras, poses, and trajectories into a runnable physical simulation. Today this process still depends on brittle workflow glue across visual perception tools and simulators: manual tuning of visual foundation models, mesh cleanup, coordinate frame alignments, etc. We introduce \textit{Agentic Real2Sim}, a framework for generalized physical world modeling with vision-language agents that converts a real-world recording of object-robot interaction into a simulatable episodic twin, and connects the resulting twin to downstream policy fine-tuning and evaluation. We evaluate Agentic Real2Sim on rigid-object manipulation, deformable-object interaction, and humanoid motion scenes, spanning domains that are usually handled by separate Real2Sim pipelines. The framework's agentic decisions can be driven by an open-weight VLM backend at a small fraction of the cost of frontier models, while attaining a comparable conversion success rate. The framework further supports custom scene conversion, fine-tuning of a pretrained policy with data generated from converted episodes, and works effectively as a surrogate for real-world policy evaluation. The project site, including code is available at https://agentic-real2sim.github.io.
We present R2HandoverSim, a simulation benchmark for robot-to-human (R2H) object handovers. Although R2H handover methods have advanced rapidly, the lack of standardized evaluation protocols impedes objective comparison. Our benchmark enables reproducible evaluation by systematically comparing four baselines on their predicted shared grasp poses. We conduct a user study with 30 participants, analyze baseline performance, and show that simulation results correlate with real-world evaluation outcomes. Crucially, five complementary metrics (planning feasibility, reachability, grasp stability, grasp affordance, and safety) better reflect user-perceived handover quality than overall success rate alone. Website and code: https://robot-future.github.io/r2handoversim/.