Enhancing Sim2Real Transfer for Torque-Controlled Robots through Real2Sim Dynamics Estimation and Reinforcement Learning

The sim-to-real gap remains a critical challenge in robotics, hindering the deployment of algorithms trained in simulation to real-world systems. We propose a flexible Real-to-Sim-to-Real (RSR) framework whose central contribution is an information-theoretic cost function that explicitly accounts for sim-to-real discrepancies. This cost balances two objectives, completing the task and steering the policy to collect real-world samples that are maximally informative for improving transfer. It can be integrated seamlessly into existing reinforcement learning algorithms (e.g., PPO, SAC) and ensures a balanced exploration of critical regions in the real domain. The framework treats differentiable simulation as optional: when a differentiable simulator is available, the collected informative data can also be used to tune simulator parameters. We implement the framework with the MuJoCo MJX platform and demonstrate its generality by evaluating on both manipulation tasks with a 6-DOF robotic arm and locomotion tasks on a legged robot. Empirical results show that our RSR loop yields more efficient data acquisition and substantially improves task performance in real-world that achieves a smoother sim-to-real transfer.

In recent years, reinforcement learning (RL) has shown remarkable success in robotics when a fast and accurate simulator is available for a given task. When using RL and simulation, more simulator realism is generally beneficial but becomes harder to obtain as robots are deployed in increasingly complex and widescale domains. In such settings, simulators will likely fail to model all relevant details of a given target task and this observation motivates the study of sim2real with simulators that leave out key task details. In this paper, we formalize and study the abstract sim2real problem: given an abstract simulator that models a target task at a coarse level of abstraction, how can we train a policy with RL in the abstract simulator and successfully transfer it to the real-world? Our first contribution is to formalize this problem using the language of state abstraction from the RL literature. This framing shows that an abstract simulator can be grounded to match the target task if the grounded abstract dynamics take the history of states into account. Based on the formalism, we then introduce a method that uses real-world task data to correct the dynamics of the abstract simulator. We then show that this method enables successful policy transfer both in sim2sim and sim2real evaluation.

While sim2real efforts are necessary for effective policy transfer to hardware, there is such a thing as too much of a good thing. We argue that sim2real efforts have led to misaligned incentives with policy learning, resulting in simulator lock in and poor policy exploration due to the unreasonable constraints imposed by the real world. We offer a diagnosis and explanation of the current status of the problem, and propose a potential solution via a sim2sim2real paradigm that leverages the robot's kinematics as the sole design constraint.