Physical AI for Intralogistics: Benchmarking the NVIDIA Sim-to-Real Ecosystem for Cosmos-Enhanced COMPASS Navigation on Industrial Mobile Robots

Recent years have witnessed significant progress in autonomous navigation using reinforcement learning. However, existing approaches largely emphasize reinforcement learning framework design, such as input representations, action spaces, and reward functions, while providing limited analysis of sim-to-real transfer and insufficient insight into how training strategies affect real-world deployment performance. To bridge this gap, we not only introduce an effective RL framework but also present a complete training and deployment pipeline, along with a systematic empirical study that disentangles the key factors affecting sim-to-real transfer in reinforcement learning-based navigation, including sensor noise, perception failures, system latency, and control response. Building on insights from this analysis, we introduce perturbation-aware fine-tuning, a post-training adaptation strategy that improves transfer robustness by explicitly accounting for empirically identified domain discrepancies. To further mitigate perception degradation and enhance control smoothness in real-world deployment, we propose a Transformer-based temporal reasoning policy that leverages short-horizon observation for navigation control. We quantitatively evaluate how individual sim-to-real perturbations and training design choices impact navigation performance across environments. Experimental results demonstrate that the proposed training strategy and policy architecture outperform learning-based baselines in both static and dynamic environments, while achieving performance comparable to optimization-based planners in static settings. We validate our approach through real-world deployment on multiple robotic platforms, including aerial and legged robots, across navigation-centric tasks such as exploration and inspection, demonstrating zero-shot sim-to-real transfer.

Learning robust navigation policies remains a core challenge in robotics. Offline imitation learning suffers from distribution shift and compounding errors at rollout, while reinforcement learning requires reward engineering and learns inefficiently. In this paper, we propose NavOL, an online imitation learning paradigm that interacts with a simulator and updates itself using expert demonstrations gathered online. Built upon a pretrained navigation diffusion policy that maps local observations to future waypoints, NavOL trains in a rollout update loop: during rollout, the policy acts in the simulator and queries a global planner which has privileged access to the global environment for the optimal path segment as ground truth trajectory labels; during update, the policy is trained on the online collected observation trajectory pairs. This online imitation loop removes the need for reward design, improves learning efficiency, and mitigates distribution shift by training on the policy own explored rollouts. Built on IsaacLab with fast, high-fidelity parallel rendering and domain randomization of camera pose and start-goal pairs, our system scales across 50 scenes on 8 RTX 4090 GPUs, collecting over 2,000 new trajectories per hour, each averaging more than 400 steps. We also introduce an indoor visual navigation benchmark with predefined start and goal positions for zero-shot generalization. Extensive evaluations on simulation benchmarks, including the NavDP benchmark and our proposed benchmark, as well as carefully designed real-world experiments, demonstrate the effectiveness of NavOL, showing consistent performance gains in online imitation learning.

Vision-based autonomous navigation for low-cost robots remains a fundamental challenge, primarily due to the significant gap between simulated training environments and real-world operational conditions. Direct policy transfer from simulation is often ineffective, while training exclusively on real data is impractical. We propose a hybrid transfer learning framework that effectively bridges the sim-to-real gap by combining domain randomization with feature-level domain adaptation. Our method employs a dual convolutional variational autoencoder architecture with a shared decoder, trained on an extensive set of 45225 simulated images and a minimal set of only 4556 real-world samples. This architecture learns a compact, common latent representation space that aligns the distributions of both domains. The adaptation process is further enhanced by two complementary data augmentation techniques designed to expand the limited real-world data. Experimental evaluation demonstrates that our method achieves an average success rate of almost 91% on image classification tasks for real-world indoor navigation, significantly outperforming both simulation-only and real-world-only training. We validate these findings through a direct, real-world deployment, where the proposed policy successfully guides a low-cost robot in a reactive exploration task. Furthermore, we validate the model's efficiency through a rigorous computational estimation, confirming its suitability for resource-constrained embedded platforms such as the Raspberry Pi 4 and NVIDIA Jetson Nano. This work presents a practical solution for developing effective and efficient navigation policies for low-cost robotic systems.