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=KtI 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.
Contact-rich manipulation requires force sensitivity, but many robot arms lack dedicated force sensors due to their high cost. We present Neural External Torque Estimation (NEXT), a data-driven method that estimates external joint torques without needing any dedicated force sensors. NEXT trains in 1 minute from only 10 minutes of free-motion data, yet achieves estimates comparable to dedicated joint-torque sensors. NEXT enables force-feedback teleoperation on low-cost arms and improves policy learning through Force-Informed Re-Sampling Training (FIRST), which up-samples pre-contact and contact segments during behavior cloning. Across five long-horizon tasks, FIRST outperforms prior force-aware policies by over 17% in task progress. Together, NEXT and FIRST bring force-aware teleoperation and policy learning to off-the-shelf robots without additional sensing hardware. Video results and code are available at https://jasonjzliu.com/factr2
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/
Satoshi Yamamori, Koji Ishihara, Kenjiro Minamikawa +4
Contact-rich manipulation requires policies to infer interaction state from signals that are often weakly observable through vision and kinematics alone. Action Chunking with Transformers (ACT) has shown strong performance in fine-grained manipulation, but many deployments collect demonstrations through leader-follower teleoperation, where tracking error between commanded leader motion and executed follower motion implicitly encodes contact, resistance, and constraint violation. This paper examines whether ACT's apparent force-awareness depends on this hidden interaction cue. We introduce an observation-centric ACT variant that predicts future follower joint states instead of leader commands, thereby removing the teleoperation-induced discrepancy signal while preserving the rest of the learning pipeline. We then evaluate whether simple joint-torque proxies, derived from onboard motor current or joint effort, can recover contact-aware behavior without external force/torque sensors. Across four real-world tasks spanning surface following, insertion, stiffness discrimination, and force-based stopping, removing the implicit cue leads to severe failures in force-critical phases. In contrast, torque-augmented policies recover robust contact behavior and improve the base ACT policy. These results demonstrate that, on real hardware, the implicit teleoperation cue is a recoverable source of force-awareness, where torque signals are available, a simple proxy matches, surpasses, or further enhances it.