MuJoCable: Reduced-Order Surface-Routed Cable Transmission for Tendon-Driven Robots
Authors: Yi Zhang, Qi Shao, Yicong Lin, Muyuan Ma, Tao Sun, Yue Xie
Abstract
Tendon transmissions reduce distal inertia and add compliance, yet routing, slack, and friction govern motion and force transfer. Mainstream rigid-body robotics simulators such as MuJoCo do not jointly resolve moving noncircular contact, unilateral tension, and segment friction. We present MuJoCable, which adds a reduced-order, configuration-dependent cable transmission to MuJoCo. Its routing algorithm jointly optimizes an ordered path across moving analytic and mesh surfaces. A unilateral axial law, directional Capstan propagation, and nodal virtual work map this path to segment tensions and body forces. The warm-started engine plugin applies these forces during simulation and exposes route and load states for design. Pulley benchmarks recover analytical transmission relations with a Capstan-ratio error below 0.5%. On the underactuated 18-joint SpiRobs, MuJoCable reveals friction-driven load growth and proximal redistribution of joint rotation that the native tendon does not represent. Hardware tests on SpiRobs and a tendon-route-coupled finger reproduce observed motion sequences. By making physical threading executable, MuJoCable brings transmission sources of the simulation-to-reality gap into route, cable, and actuator design before fabrication.
Linear-deformable manipulation remains challenging due to the complex deformations of objects such as cables and ropes. Prior data-driven approaches, particularly imitation learning, have shown some promise in narrowly defined settings but typically require thousands of demonstrations for specific tasks and cable types, limiting scalability and generalization. We introduce a sim-to-real reinforcement learning (RL) framework for multi-stage cable routing that leverages GPU-parallelized simulation to approximate linear deformable behaviors. Training across thousands of parallel simulations enables the learned policies to generalize across diverse cable geometries and deformation patterns. To bridge the sim-to-real gap, we propose a novel deployment strategy that combines a Simulation In the LOop (SILO) execution framework, localized RL policies, and robust cable state estimation. On real-world cable routing tasks, our approach achieves higher success rates and 2x reduction in cycle times compared to prior state-of-the-art learning methods. To our knowledge, this is the first successful sim-to-real transfer of RL policies for multi-stage cable routing. Videos and additional visualizations are available at https://silo-cable-routing.github.io/
Learning contact-rich, whole-body manipulation for soft continuum robots is held back by the lack of simulation infrastructure that has accelerated rigid-robot manipulation. Existing soft robot simulators are physically grounded but lack the contact handling, actuation support, or learning integration needed for contact-rich manipulation; rigid-body approximations offer these capabilities but sacrifice physical grounding. We bridge this gap for tendon-driven continuum robots (TDCRs) by deriving a continuum-mechanics-informed discretization that places the soft robot natively inside MuJoCo, unifying tendon forces, body contact, and dynamics in a single physics pipeline. We validate the simulator against a Cosserat rod reference (static and dynamic) and real TDCR hardware. We then train state-based imitation learning policies via teleoperation in simulation and deploy them zero-shot to a physical 3-segment TDCR on a 7-DoF Franka arm across two contact-rich manipulation tasks. To our knowledge, this is the first demonstration of sim-to-real transfer for contact-rich manipulation with continuum robots.
Chengnan Shentu, Nicholas Baldassini, Tongjia Zheng +2
Steering Cable-Driven Parallel Robots (CDPRs) beyond their Wrench-Feasible Workspace (WFW) augments their capabilities in challenging scenarios such as during aggressive maneuvers or following a cable failure. In this context, although the determination of cable tensions is a well-studied topic, only a few approaches address these scenarios. Therefore, this paper introduces an extended version of the Analytic Center method as a criterion for selecting cable tensions outside the WFW while maintaining differentiability and including non-linear constraints. Notably, the proposed method maintains continuous and differentiable tension profiles, ensures fast real-time convergence to a unique solution, and, in contrast to other slack-based formulations, relegates wrench errors to a negligible area of the WFW. Its superiority in terms of smoothness and wrench error is confirmed via Pareto dominance with respect to the leading state-of-the-art method. Lastly, the effectiveness of the method is demonstrated through numerical experiments.
Domenico Dona', Vincenzo Di Paola, Alberto Trevisani +1