Layout-independent actuation allocator for fin-actuated marine robots

Sim-to-real transfer in robot learning is often limited by discrepancies between the ideal actuator dynamics assumed during policy training and the nonlinear, hardware-dependent behavior of physical motors. While conventional approaches attempt to bridge this gap by increasing simulator fidelity through system identification, domain randomization, or learned actuator models, we introduce an alternative paradigm: actuator reality shaping. Instead of modifying the simulator to match the real world, our method shapes the closed-loop behavior of physical actuators to match the idealized second-order reference dynamics used in simulation. By equipping each joint with a two-degree-of-freedom feedforward--feedback controller, we decouple reference-response shaping from robust stabilization, thereby providing a standardized actuator interface for reinforcement learning policies. As a result, policies trained only with the prescribed reference model can be deployed zero-shot on real hardware without task-level fine-tuning or learned actuator models. We validate the approach on a single-joint high-gear-ratio servo under external loads and a 7-DOF robotic arm reaching task, where actuator reality shaping substantially reduces sim-to-real tracking error and improves zero-shot task performance compared with standard servo-control and representative real-to-sim-to-real baselines. We further demonstrate zero-shot transfer on a wheeled-legged robot driving over a slope and a humanoid robot walking, suggesting that actuator reality shaping can serve as a reusable interface for robot learning across diverse hardware platforms. Project page: https://syamamori.github.io/ActuatorRealityShaping.github.io/

Underwater robots often operate near delicate targets where high-power thrusters resuspend sediments and induce turbulence, degrading image quality at the sensor input. Conventional controllers optimize vehicle-centric objectives, such as tracking and stability, without accounting for the impact of actuation on sensing. We address this actuation-to-perception coupling by exploiting redundancy in over-actuated platforms. For an eight-thruster ROV, multiple thrust allocations can yield the same motion; we search this null space to minimize predicted disturbance in a task-relevant target region while enforcing motion constraints. Our method uses a control-oriented thruster-wake proxy derived from actuator-disk theory with directional attenuation and validated by PIV ($R^2 = 0.99$ near the wake axis; $R^2 > 0.82$ in the primary wake region), together with a real-time redundancy-resolving allocator running at 10 Hz (45 ms/solve). Across 440 trials, the approach reduces target-region particle velocity by 67% ($p < 0.001$), improves 3D reconstruction RMSE by 55% versus a disturbance-unaware baseline ($1.9 \pm 0.4$ mm vs. $4.3 \pm 1.8$ mm), and achieves a 98.5% reconstruction success rate. The framework supports autonomous scanning, which is quantitatively evaluated, and operator-assisted inspection, which is demonstrated in the supplementary materials.

Differentiable simulators have advanced policy learning and model-based control, yet actuator dynamics remain an important source of sim-to-real error. This is particularly acute on low-cost platforms, where the linear current-to-torque relation $τ= K_tI$ becomes unreliable during commanded-target tracking because of friction, hysteresis, backlash, and thermal effects. We present NeuralActuator, a neural actuator model that jointly predicts (i) a simulator-equivalent generalized-effort surrogate for trajectory propagation on low-cost servo platforms, (ii) external force with a contact-probability gate for sensorless force perception, and (iii) a motor-condition score for the supervised joint. We also introduce the Neural Actuation Dataset (NAD), collected with a twin-arm teleoperation system that records robot states and actuator telemetry together with external-force labels. The torque-surrogate head is trained through differentiable simulation from pose trajectories without direct generalized-effort labels, while the force, gate, and motor-condition heads receive direct supervision. A Transformer captures temporal dependencies while supporting real-time inference. We evaluate NeuralActuator on a 5-DoF OpenManipulator-X, a 6-DoF SO-101, and a 7-DoF Franka Emika Panda, spanning three actuator families and platforms costing approximately USD 500 to over USD 30,000. The low-cost platforms support dynamics and force evaluation, while the offline Franka experiment provides an additional payload-force-estimation benchmark. Experiments further demonstrate its application for motor condition estimation on OpenManipulator-X and improved behavior-cloning performance when NeuralActuator is used as a pretrained module.