Residual Policy Learning

We introduce Distribution Contractive Reinforcement Learning (DICE-RL), a framework that uses reinforcement learning (RL) as a "distribution contraction" operator to refine pretrained generative robot policies. DICE-RL turns a pretrained behavior prior into a high-performing "pro" policy by amplifying high-success behaviors from online feedback. We pretrain a diffusion- or flow-based policy for broad behavioral coverage, then finetune it with a stable, sample-efficient residual off-policy RL framework that combines selective behavior regularization with value-guided action selection. Extensive experiments and analyses show that DICE-RL reliably improves performance with strong stability and sample efficiency. It enables mastery of complex long-horizon manipulation skills directly from high-dimensional pixel inputs, both in simulation and on a real robot. Project website: https://zhanyisun.github.io/dice.rl.2026/.

Robotic systems deployed beyond controlled environments encounter abrupt and unobserved dynamics shifts that induce substantial transient performance loss, even when the nominal closed loop remains locally stabilizing. We formulate rapid inference-time recovery for physical AI as a constrained residual learning problem, in which an online correction added to a frozen reinforcement learning policy is regulated to minimize recovery time while remaining inside the robustness margin of the nominal controller. We specifically focus upon the regulation of residual's corrective authority relative to an already competent frozen policy. The learned residual produces bounded action-space corrections online, and a Stability Alignment Gate regulates this corrective authority through magnitude constraints, directional coherence, performance-conditioned regulation, and adaptive gain modulation. The method requires no environment resets, policy retraining, explicit system identification, or privileged shift information. Across mid-episode changes in actuation, mass, and contact conditions, it reduces recovery time relative to frozen SAC by up to 87% on Go1, 48% on Cassie, 30% on H1, and 20% on Scout in simulation, while preserving near-nominal steady-state performance. The framework is also characterized on two physical robots, a Trossen ViperX manipulator and an AgileX Scout Mini, cutting recovery time by 19.5% on hardware without modifying onboard controller or accessing shift information.

Contact-rich micromanipulation in microfluidic flow is challenging because small disturbances can break pushing contact and induce large lateral drift. We study planar cell pushing with a magnetic rolling microrobot that tracks a waypoint-sampled reference curve under time-varying Poiseuille flow in simulation. We propose a hybrid controller that augments a nominal MPC with a learned residual policy trained by SAC. The policy outputs a bounded 2D velocity correction that is contact-gated, so residual actions are applied only during robot-cell contact, preserving reliable approach behavior and stabilizing learning. All methods share the same actuation interface and speed envelope for fair comparisons. Simulation results show improved robustness and tracking accuracy over pure MPC and PID under nonstationary flow, with generalization from a clover training curve to unseen circle and square trajectories. A residual-bound sweep identifies an intermediate correction limit as the best trade-off, which we use in all benchmarks.

Imitation learning (IL) has shown strong potential for contact-rich precision insertion tasks. However, its practical deployment is often hindered by covariate shift and the need for continuous expert monitoring to recover from failures during execution. In this paper, we propose Trajectory Editing Residual Dataset Aggregation (TER-DAgger), a scalable and force-aware human-in-the-loop imitation learning framework that mitigates covariate shift by learning residual policies through optimization-based trajectory editing. This approach smoothly fuses policy rollouts with human corrective trajectories, providing consistent and stable supervision. Second, we introduce a force-aware failure anticipation mechanism that triggers human intervention only when discrepancies arise between predicted and measured end-effector forces, significantly reducing the requirement for continuous expert monitoring. Third, all learned policies are executed within a Cartesian impedance control framework, ensuring compliant and safe behavior during contact-rich interactions. Extensive experiments in both simulation and real-world precision insertion tasks show that TER-DAgger improves the average success rate by over 37% compared to behavior cloning, human-guided correction, retraining, and fine-tuning baselines, demonstrating its effectiveness in mitigating covariate shift and enabling scalable deployment in contact-rich manipulation.

Robotic assembly presents a long-standing challenge due to its requirement for precise, contact-rich manipulation. While simulation-based learning has enabled the development of robust assembly policies, their performance often degrades when deployed in real-world settings due to the sim-to-real gap. Conversely, real-world reinforcement learning (RL) methods avoid the sim-to-real gap, but rely heavily on human supervision and lack generalization ability to environmental changes. In this work, we propose a hybrid approach that combines a simulation-trained base policy with a real-world residual policy to efficiently adapt to real-world variations. The base policy, trained in simulation using low-level state observations and dense rewards, provides strong priors for initial behavior. The residual policy, learned in the real world using visual observations and sparse rewards, compensates for discrepancies in dynamics and sensor noise. Extensive real-world experiments demonstrate that our method, SPARR, achieves near-perfect success rates across diverse two-part assembly tasks. Compared to the state-of-the-art zero-shot sim-to-real methods, SPARR improves success rates by 38.4% while reducing cycle time by 29.7%. Moreover, SPARR requires no human expertise, in contrast to the state-of-the-art real-world RL approaches that depend heavily on human supervision.

Traversing narrow paths is challenging for humanoid robots due to the sparse and safety-critical footholds required. Purely template-based or end-to-end reinforcement learning-based methods suffer from such harsh terrains. This paper proposes a two stage training framework for such narrow path traversing tasks, coupling a template-based foothold planner with a low-level foothold tracker from Stage-I training and a lightweight perception aided foothold modifier from Stage-II training. With the curriculum setup from flat ground to narrow paths across stages, the resulted controller in turn learns to robustly track and safely modify foothold targets to ensure precise foot placement over narrow paths. This framework preserves the interpretability from the physics-based template and takes advantage of the generalization capability from reinforcement learning, resulting in easy sim-to-real transfer. The learned policies outperform purely template-based or reinforcement learning-based baselines in terms of success rate, centerline adherence and safety margins. Validation on a Unitree G1 humanoid robot yields successful traversal of a 0.2m wide and 3m long beam for 20 trials without any failure.

Numerous locomotion controllers have been designed based on Reinforcement Learning (RL) to facilitate blind quadrupedal locomotion traversing challenging terrains. Nevertheless, locomotion control is still a challenging task for quadruped robots traversing diverse terrains amidst unforeseen disturbances. Recently, privileged learning has been employed to learn reliable and robust quadrupedal locomotion over various terrains based on a teacher-student architecture. However, its one-encoder structure is not adequate in addressing external force perturbations. The student policy would experience inevitable performance degradation due to the feature embedding discrepancy between the feature encoder of the teacher policy and the one of the student policy. Hence, this paper presents a privileged learning framework with multiple feature encoders and a residual policy network for robust and reliable quadruped locomotion subject to various external perturbations. The multi-encoder structure can decouple latent features from different privileged information, ultimately leading to enhanced performance of the learned policy in terms of robustness, stability, and reliability. The efficiency of the proposed feature encoding module is analyzed in depth using extensive simulation data. The introduction of the residual policy network helps mitigate the performance degradation experienced by the student policy that attempts to clone the behaviors of a teacher policy. The proposed framework is evaluated on a Unitree GO1 robot, showcasing its performance enhancement over the state-of-the-art privileged learning algorithm through extensive experiments conducted on diverse terrains. Ablation studies are conducted to illustrate the efficiency of the residual policy network.