Leveraging Human-In-The-Loop Demonstrations in Reinforcement Learning for Digital Twin-Driven Robot Flexibility

Learning effective robot control policies on physical hardware is challenging due to costly data collection and the difficulty of reward specification. Prior work has incorporated demonstrations into reinforcement learning (RL), yet existing approaches either require large numbers of demonstrations or depend on continuous human intervention during training. To address these limitations, we present AutoSERL, a framework that leverages a single demonstration to fully automate the intervention process in real-world robot RL. The framework includes three complementary mechanisms to accomplish certain tasks: a sliding window intervention mechanism that continuously guides exploration to prevent local optima and unsafe deviations, a safety recovery mechanism that detects and corrects failure states via predefined trajectory recovery points, and an intervention termination criterion that automatically disables guidance once the policy can independently complete the task, preserving its exploration advantage. We evaluate AutoSERL on six contact-intensive manipulation tasks across two robot platforms, spanning insertion, hanging, and hinge-based tasks. AutoSERL consistently outperforms SERL initialized with 20 demonstrations, behavior cloning, and MILES -- a dedicated one-shot imitation learning baseline -- across all tasks while matching HIL-SERL, achieves 100% success rate on insertion tasks, and demonstrates improved robustness to positional variations, all from a single demonstration. Code and videos are available on our project website: https://autoserl.github.io/.

Imitation learning enables robots to acquire manipulation skills from demonstrations, but the resulting policies can fail outside the training data, while collecting more demonstrations requires substantial human effort. Human-in-the-loop reinforcement learning uses corrective feedback during online training, but typically learns the complete task policy rather than refining a pretrained imitation policy. We introduce Res-HIL, a human-in-the-loop residual reinforcement learning framework that learns corrective actions on top of a frozen imitation policy. Each human intervention provides two complementary learning signals: direct supervision of the residual policy and reward shaping of preceding autonomous behavior. Res-HIL combines these signals with zero initialization of the residual policy to stabilize and accelerate online learning. We evaluate Res-HIL on five contact-rich manipulation tasks spanning high-precision and long-horizon behaviors. With only 20 initial demonstrations, Res-HIL outperforms state-of-the-art full-policy human-in-the-loop reinforcement learning and residual fine-tuning without human guidance on every task after ten minutes of online training. Res-HIL improves its pretrained base policies and outperforms imitation policies trained with five times more demonstrations. An ablation study shows that direct residual supervision is critical to performance, while intervention-aware reward shaping substantially improves training efficiency.

Human-in-the-loop reinforcement learning systems achieve near-perfect success on the workstation where they are trained, but collapse when the same robot is moved to a workstation a few meters away due to shifts in the visual input distribution caused by new lamp positions and window light. Re-collecting demonstrations and re-running HIL on every workstation is incompatible with deployment, and naively fine-tuning on shifted-light data triggers catastrophic forgetting of the source workstation. To close this cross-domain gap, we present RoHIL, an offline fine-tuning framework that uses no extra real-robot interaction. RoHIL combines (i) a world-model-based image relighter that re-synthesises the visual stream of source-workstation trajectories under multiple virtual HDRI environments, leaving actions and rewards real; (ii) Illumination-Retention Replay (IRR), a data-level anti-forgetting mechanism that interleaves relit adaptation transitions with original-light retention transitions to preserve source-workstation Bellman coverage; and (iii) an anchored Bellman-actor regulariser that constrains representation and policy drift from the original source-workstation policy. Across four real-robot manipulation tasks under significant cross-workstation illumination variations, RoHIL substantially improves shifted-light performance where standard HIL-RL collapses, while preserving source-workstation performance, eliminating the need to re-collect data and retrain for every new workstation and environment. Project page: https://anonymous4365.github.io/RoHIL/