Robot Failure Recovery

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10 papers in the last four weeks, against 2 the four weeks before. 0.1% of all new papers.

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Latest papers 49

Jun 8, 2026cs.RO

Back to the Familiar Future: Failure Recovery for VLA Policies via Pre-Imagined Milestone Selection

Vision-language-action (VLA) policies can deviate from nominal trajectories during manipulation, even when tasks remain physically feasible. Recovering from these deviations is challenging, as they push the policy into unfamiliar state spaces where direct re-planning frequently destabilizes action sequences. We propose Back to the Familiar Future (B2FF), a recovery framework for foresight-driven VLAs that leverages future visual conditioning as a recovery interface. Before execution, the VLA generates a milestone bank of familiar future states conditioned on the clean initial observation. At recovery time, a recoverability-aware selector selects a recovery milestone from this bank and enforces it as a fixed visual goal. This enables the VLA to robustly map off-trajectory observations back to a familiar future. On failure-injected LIBERO, under controlled recovery timing aligned with the injected failure, B2FF increases the average success rate of a baseline VLA from 56.3% to 74.0%, demonstrating that pre-imagined milestones can guide recovery without fine-tuning the low-level action generator.

Suyeon Shin, Juwon Kim, Hyeonbin Park +4

Seoul National University · Yonsei University · Soongsil University

Robot Failure Recovery Robotic Manipulation Robot Task Planning Vision-Language-Action Models

Jun 8, 2026cs.RO

CG-MuTra: Continuously-Gated Multi-Terrain Adaptive Recovery for Unified Humanoid Fall Recovery and Locomotion

Falling is an inherent risk for humanoid robots operating in unstructured environments. Existing reinforcement learning methods that leverage expert motion priors are predominantly trained on flat-ground fall-recovery tasks and typically rely on hard switching between separate recovery and locomotion controllers. As a result, such policies struggle to achieve smooth and robust recovery behaviors when deployed on complex terrains such as slopes and gravel. This paper presents \textbf{CG-MuTra}, a unified continuously-gated multi-scale discriminator framework for multi-terrain adaptive fall recovery. CG-MuTra introduces a proprioceptively-derived continuous gate

α= f(z_{\mathrm{root}}, s)

that softly blends three discriminators operating at different temporal horizons: frame-level stability (

Φ_{\mathrm{frame}}

,

H=1

), temporal smoothness (

Φ_{\mathrm{seq}}

,

H=5

), and gait periodicity (

Φ_{\mathrm{gait}}

,

H=10

). This design enables seamless recovery-to-locomotion transitions without explicit mode switching. Furthermore, we propose a Terrain-Pose Risk Coupling Sampler (TPRCS) that explicitly couples dangerous edge initial poses with terrain dynamics during training, forming a closed-loop synergy with the terrain-privileged shaping term

Ξ_κ

. We validate CG-MuTra on a Unitree G1 humanoid across grass, slopes (

10^\circ

--

15^\circ

), and gravel in both simulation and hardware. Experimental results demonstrate that CG-MuTra achieves smooth, highly robust fall recovery and locomotion transitions across multiple terrains while maintaining a single deployable policy.

Xiaoyu Xu, Zhiming Chen, Yuenan Zhao +2

School of Control Science and Engineering, Shandong University, Jinan, 250061, China · Key Laboratory of Machine Intelligence and System Control, Ministry of Education, China

Humanoid Robot Locomotion Robot Failure Recovery Terrain-Aware Robot Locomotion Robot Locomotion Robust RL Humanoid Robotics

Jun 4, 2026cs.AI

AEGIS: A Backup Reflex for Physical AI

Long-horizon robot manipulation tends to fail gradually: one bad step degrades the state, and the policy spirals into a basin from which it cannot recover. The failure is often visible before it happens. We introduce AEGIS (Activation-probe Early-warning, Gated Inference Switching), a selective escalation method that uses a lightweight probe on a weak policy's frozen activations to detect high-risk steps while there is still time to act. When the probe flags a step, control switches to a stronger separate policy, but only for the steps that need it. On LIBERO-Spatial, AEGIS recovers 10.1% of the trajectories the weak policy alone loses, versus 4.6% for budget-matched blind escalation and 5.1% for a random-trigger placebo. These gains are significant under one-sided exact paired McNemar tests with Holm-Bonferroni adjustment over three pre-registered contrasts: +5.4pp over blind escalation, p=8.5e-6; +5.0pp over random triggering, p=1.0e-4; paired-trajectory bootstrap CIs exclude zero. AEGIS activates the stronger policy on only 38% of steps, so the lever is timing rather than compute. The probe clears its precondition with an early-window AUROC of 0.764, 95% CI [0.70, 0.84], read from the weak-policy path over the first 30% of trajectory steps before any handoff. We pre-register the full analysis plan, including a conditional recovered-task-rate estimand and explicit kill criteria, and confirm the result on 700 common-random-number episodes per arm, with nA-fail=646.

Josef Chen

KAIKAKU

Robot Policy Learning Long-Horizon Robotic Manipulation Robot Failure Detection Robot Failure Recovery

Jun 4, 2026cs.RO

Preserving Full 6-DOF Actuation Under Abrupt Total Rotor Failures: Passive Fault-Tolerant Flight Control Using a Biaxial-Tilt Hexacopter

Abrupt total rotor failures can invalidate nominal allocation despite remaining wrench capability. This paper develops an allocator-layer passive fault-tolerant control (AL-PFTC) scheme for overactuated vector-thrust aerial vehicles. Analysis of convexified attainable force and torque spaces at horizontal hover compares biaxial- and uniaxial-tilt configurations and screens fault cases using prescribed reserve thresholds. Instantaneous wrench loss relative to these reserves characterizes the initial redistribution burden. AL-PFTC adapts the allocation matrix using a virtual error derived from filtered wrench commands and an onboard external wrench estimate, with adaptive parameter bounds constructed from right inverses. Joint analysis including estimator residuals and filter dynamics establishes local uniform ultimate boundedness for position and attitude regulation under the stated conditions. Controller-layer passive fault-tolerant control (CL-PFTC) provides a reference with nominal allocation and observer compensation. Both share a nominal tracking baseline and run at 600 Hz on an STM32H753 without explicit fault identification, fault-mode switching, or online optimization. Comparisons show that AL-PFTC satisfies the recovery criterion in more tested hovering cases than CL-PFTC. Additional experiments using only onboard sensing, including indoor tracking under wind disturbance, outdoor tracking under wind and low-temperature conditions, narrow-frame traversal, and contact-based aerial writing, further validate the robustness of AL-PFTC in complex operational environments.

Yipeng Yang, Yiqiao Tang, Hao Zhang +6

Aerial Robotics Robot Failure Recovery Robust Control Fault-Tolerant Control Adaptive Control

May 28, 2026cs.RO

Phase-Conditioned Imitation Learning with Autonomous Failure Recovery for Robust Deformable Object Manipulation

This paper presents a phase-conditioned, force-aware framework for robust deformable object manipulation. Standard imitation learning policies such as Action Chunking with Transformers (ACT) rely on a Markovian assumption at inference, causing state aliasing when visually similar observations require contradictory actions and preventing autonomous recovery from execution failures. We address this with a closed-loop hierarchical architecture. A FiLM-conditioned ACT encoder modulates feature extraction based on the current task phase, enabling a single unified policy to produce phase-specific behaviors while sharing action dynamics across phases. A multi-modal phase predictor fusing visual, force, and pose feedback estimates the phase in real time, detecting contact failures that are invisible to vision alone and autonomously triggering recovery trajectories. The system is completed by a hybrid impedance controller for compliant execution and a haptic teleoperation interface for force-aware data collection. Ablation studies show that FiLM-based modulation significantly outperforms both unconditioned and token-level conditioned baselines, and t-SNE analysis confirms that FiLM induces well-separated, phase-specific feature representations. Validated on hanging and removing a T-shirt with dual arms, the closed-loop system improves the hanging success rate from 56% to 87% through autonomous error recovery. Code and videos: https://leledeyuan00.github.io/phaser/

Dayuan Chen, Kai Tang, Yukuan Zhang +2

Bimanual Robotic Manipulation Deformable Object Manipulation Robot Failure Recovery Robotics Imitation Learning Robot Imitation Learning

May 18, 2026cs.RO

Unified Walking, Running, and Recovery for Humanoids via State-Dependent Adversarial Motion Priors

We propose a unified reinforcement learning framework that enables a single policy to perform walking, running, and fall recovery on the Unitree G1 humanoid robot, validated on physical hardware without any explicit mode-switching command at deployment. The framework extends Adversarial Motion Priors (AMP) by replacing the conventional global reference distribution with a state-dependent gate that routes each training transition to one of two discriminators: a dedicated recovery discriminator and a velocity-conditioned locomotion discriminator that jointly covers walking and running. The gate is defined by a single fixed threshold on projected gravity: the recovery discriminator is activated when body tilt exceeds approximately

37^\circ

from vertical (

|g_z+1|>0.6

); otherwise the locomotion discriminator is used, with the normalized commanded velocity serving as a condition that selects the appropriate reference trajectory between walk and run clips. Only three LAFAN1 reference clips are required to regularize the complete behavior set. At deployment, a single frozen ONNX policy executes at 50,Hz with no runtime mode logic; hardware experiments demonstrate successful recovery from both prone and supine falls and smooth walk-to-run transitions under the same controller.

Yidan Lu, Yichao Zhong, Liu Zhao +2

The University of Hong Kong, Hong Kong SAR, China.

Humanoid Robot Locomotion Robot Failure Recovery RL for Legged Locomotion Policy Learning Humanoid Robotics

May 12, 2026cs.RO

From Reaction to Anticipation: Proactive Failure Recovery through Agentic Task Graph for Robotic Manipulation

Although robotic manipulation has made significant progress, reliable execution remains challenging because task failures are inevitable in dynamic and unstructured environments. To handle such failures, existing frameworks typically follow a stepwise detect-reason-recover pipeline, which often incurs high latency and limited robustness due to delayed reasoning and reactive planning. Inspired by the human capability to anticipate and proactively plan for potential failures, we introduce AgentChord, an agentic system that models a manipulation task as a directed task graph. Before execution, this graph is enriched with anticipatory recovery branches that specify context-aware corrective behaviors, enabling immediate and targeted responses when failures occur. Specifically, AgentChord operates through a choreography of specialized agents: a composer that structures the nominal task graph, an arranger that augments the graph with anticipatory recovery branches, and a conductor that compiles and coordinates executable transitions using low-latency monitors to detect deviations and trigger pre-compiled recoveries without re-planning. Empirical studies on diverse long-horizon bimanual manipulation tasks demonstrate that AgentChord substantially improves success rates and execution efficiency, advancing the reliability and autonomy of real-world robotic systems. The project page is available at: https://shengxu.net/AgentChord/.

Sheng Xu, Ruixing Jin, Huayi Zhou +6

School of Data Science, The Chinese University of Hong Kong, Shenzhen · DexForce Technology, 3Shenzhen Loop Area Institute.

Long-Horizon Robotic Manipulation Bimanual Robotic Manipulation Robot Failure Recovery Robotic Manipulation Graph-Based Planning

May 10, 2026cs.RO

RePO-VLA: Recovery-Driven Policy Optimization for Vision-Language-Action Models

Vision-Language-Action (VLA) models remain brittle in long-horizon, contact-rich manipulation because success-only imitation provides little supervision for execution drift, while failed rollouts are often discarded. We introduce RePO-VLA, a recovery-driven policy optimization framework that assigns distinct roles to success, recovery, and failure trajectories. RePO-VLA first applies Recovery-Aware Initialization (RAI), slicing recovery segments and resetting history so corrective actions depend on the current adverse state rather than the preceding failure. It then learns a Progress-Aware Semantic Value Function (PAS-VF), aligning spatiotemporal trajectory features with instructions and successful references. The resulting labels salvage useful failure prefixes via reliability decay, while low-value labels mark drift and terminal breakdowns, teaching differences among nominal, failed, and corrective actions. The data engine turns adverse states into planner-generated or human-collected corrective rollouts, teaching recovery to the success manifold. Value-Conditioned Refinement (VCR) trains the policy to prefer high-progress actions. At deployment, a fixed high value (

v=1.0

) biases actions toward the learned success manifold without online failure detectors or heuristic retries. We introduce FRBench, with standardized error injection and recovery-focused evaluation. Across simulated and real-world bimanual tasks, RePO-VLA improves robustness, raising adversarial success from 20% to 75% on average and up to 80% in scaled real-world trials.

Weijia Liufu, Xiaoyu Guo, Ruiyi Chen +16

1Sun Yat-sen University · 2South China University of Technology · 3Peng Cheng Laboratory +3

VLM Robustness Robot Failure Recovery Robotics Vision-Language-Action Models Robustness of VLA Models

May 6, 2026cs.RO

Passive Fault Tolerance through Tension-to-Thrust Feed-Forward: Hybrid Input-to-State Stability for Decentralized Multi-UAV Slung-Load Transport under Abrupt Cable Severance

Abrupt cable severance in multi-UAV slung-load transport redistributes load and changes the active constraint set, leaving limited time for fault diagnosis and reconfiguration. Existing controllers rely on coordinated force allocation, peer-state exchange, or fixed cable topology, and therefore lack a certified decentralized recovery mechanism for unannounced severance. We present a passive architecture that routes each vehicle's measured cable tension directly into its altitude thrust command,

T_i^{\mathrm{ff}}=T_i

, while a surrounding proportional-derivative, anti-swing, and projection cascade preserves local tracking feasibility. The main contribution is a conditional hybrid practical input-to-state-stability certificate that composes a slack-excursion-bounded taut-cable reduction, bounded post-severance Lyapunov jumps, inter-fault decay, and per-fault-cycle contraction

ρ\in (0,1)

into an explicit recovery envelope under stated actuator, slack, and dwell assumptions. We validate the controller in Drake multibody simulation with five vehicles, a 10 kg payload, Kelvin-Voigt cables, Dryden wind, and single- and dual-severance schedules: the closed loop attains 0.312-0.328 m RMSE, 76.1-95.2 mm peak sag, and recovery within one payload-pendulum period. Disabling the identity inflates cruise error by 34-39% and peak sag by 3.6x-4.0x, identifying local tension feed-forward as the dominant passive recovery mechanism in the tested decentralized cascade.

Hadi Hajieghrary, Paul Schmitt

Independent Researcher · Reynolds & Moore

Multi-Robot Systems Robot Failure Recovery Multi-Agent Control Fault-Tolerant Control

Apr 28, 2026cs.RO

ANCHOR: A Physically Grounded Closed-Loop Framework for Robust Home-Service Mobile Manipulation

Recent advances in open-vocabulary mobile manipulation have brought robots into real domestic environments. In such settings, reliable long-horizon execution under open-set object references and frequent disturbances becomes essential. However, many failures persist. These are not caused by semantic misunderstanding but by inconsistencies between symbolic plans and the evolving physical world, manifested as three recurring limitations: (i) existing systems often rely on pre-scanned semantic maps that become inconsistent after scene changes and disturbances; (ii) they select navigation endpoints without considering downstream manipulation feasibility, causing the "arrived but inoperable" problem; and (iii) they handle anomalies through undifferentiated global replanning, which often fails to contain local errors. To address this execution inconsistency, we present ANCHOR, a physically grounded closed-loop framework that aligns symbolic reasoning with verifiable physical state during execution. ANCHOR integrates three mechanisms: (i) physically anchored task planning, which binds symbolic predicates to observable geometric anchors and re-validates them after each action; (ii) operability-aware base alignment, which ensures that navigation endpoints satisfy kinematic reachability and local collision feasibility; and (iii) minimum-responsible-layer hierarchical recovery, which localizes failures across perception, base-arm coordination, and execution layers to prevent cascading retries. Across 60 real-robot trials in previously unseen environments, ANCHOR improves task success from 53.3% to 71.7% and achieves a 71.4% recovery rate under perturbations, demonstrating that explicit physical grounding and structured failure containment are critical for robust mobile manipulation. Our project page is available at https://anchor9178.github.io/ANCHOR/ .

Jinhao Jiang, Shengyu Fang, Sibo Zuo +2

Beijing Institute of Technology

Long-Horizon Robotic Manipulation Mobile Manipulation Robot Failure Recovery Robot Task Planning

Apr 24, 2026cs.RO

RecoverFormer: End-to-End Contact-Aware Recovery for Humanoid Robots

Humanoid robots operating in unstructured environments must recover from unexpected disturbances-a capability that remains challenging for end-to-end control policies. We present RECOVERFORMER, a fully end-to-end humanoid recovery policy that learns when and how to switch among recovery behaviors-including compensatory stepping, hand-environment contact, and center-of-mass reshaping-while maintaining robust performance under model mismatch. The architecture combines a causal transformer over a 50-step observation history with two novel heads: a latent recovery mode that enables smooth transitions among distinct recovery strategies, and a contact affordance head that predicts which environmental surfaces (walls, railings, table edges) are beneficial for stabilization. We evaluate RECOVERFORMER on the Unitree G1 humanoid in MuJoCo. Trained only on open floor, RECOVERFORMER transfers zero shot to walled environments, achieving 100% recovery success across 100-300 N pushes and across wall distances from 0.25-1.4m. Under zero-shot dynamics mismatch, RECOVERFORMER reaches 75.5% at plus +25% mass, 89% under 30 ms latency, 91.5% at low friction, and 99% under compound friction, latency and mass perturbation. The learned latent modes specialize across force regimes without mode-level supervision, validated by t-SNE analysis of 300 episodes. Taken together, these results show that a single end-to-end policy can deliver multi-modal, contact aware humanoid recovery that generalizes across perturbation magnitude, contact geometry, and dynamics shift.

Zihui Liu

Stanford University

Humanoid Robot Locomotion Humanoid Robot Control Robot Failure Recovery Robot Policy Generalization Robust RL Humanoid Robotics

Apr 23, 2026eess.SY

A Case Study in Recovery of Drones using Discrete-Event Systems

Discrete-event systems and supervisory control theory provide a rigorous framework for specifying correct-by-construction behavior. However, their practical application to swarm robotics remains largely underexplored. In this paper, we investigate a topological recovery method based on discrete-event-systems within a swarm robotics context. We propose a hybrid architecture that combines a high-level discrete event systems supervisor with a low-level continuous controller, allowing lost drones to safely recover from fault or attack events and re-enter a controlled region. The method is demonstrated using ten simulated UAVs in the py-bullet-drones framework. We show recovery performance across four distinct scenarios, each with varying initial state estimates. Additionally, we introduce a secondary recovery supervisor that manages the regrouping process for a drone after it has re-entered the operational region.

Liam P. Burns, Dayse M. Cavalcanti, Felipe G. Cabral +4

Department of Electrical and Computer Engineering and Ingenuity Labs Research Institute, Queen’s University, Kingston, ON, K7L 3N6, Canada · Automation and Systems Engineering Program, Federal University of Santa Catarina, Florianópolis, SC, 88.040-900, Brazil

Dynamical Systems Aerial Robotics Multi-Robot Systems Swarm Robotics Robot Failure Recovery Multi-Robot Coordination

Apr 20, 2026cs.LG

HELM: Harness-Enhanced Long-horizon Memory for Vision-Language-Action Manipulation

Vision-Language-Action (VLA) models fail systematically on long-horizon manipulation tasks despite strong short-horizon performance. We show that this failure is not resolved by extending context length alone in the current reactive execution setting; instead, it stems from three recurring execution-loop deficiencies: the memory gap, the verification gap, and the recovery gap. We present HELM, a model-agnostic framework that addresses these deficiencies with three components: an Episodic Memory Module (EMM) that retrieves key task history via CLIP-indexed keyframes, a learned State Verifier (SV) that predicts action failure before execution from observation, action, subgoal, and memory-conditioned context, and a Harness Controller (HC) that performs rollback and replanning. The SV is the core learning contribution: it consistently outperforms rule-based feasibility checks and ensemble uncertainty baselines, and its effectiveness depends critically on access to episodic memory. On LIBERO-LONG, HELM improves task success rate by 23.1 percentage points over OpenVLA (58.4% to 81.5%), while extending the context window to H=32 yields only a 5.4-point gain and same-budget LoRA adaptation remains 12.2 points below HELM. HELM also improves long-horizon performance on CALVIN and substantially boosts recovery success under controlled perturbations. Ablations and mechanism analyses isolate the contribution of each component, and we release LIBERO-Recovery as a perturbation-injection protocol for evaluating failure recovery in long-horizon manipulation.

Zijian Zeng, Fei Ding, Huiming Yang +1

Tsinghua University · Alibaba Group · Bengbu University

Long-Horizon Robotic Manipulation Robot Failure Recovery Robotics Vision-Language-Action Models

Apr 17, 2026cs.RO

Rewind-IL: Online Failure Detection and State Respawning for Imitation Learning

Imitation learning has enabled robots to acquire complex visuomotor manipulation skills from demonstrations, but deployment failures remain a major obstacle, especially for long-horizon action-chunked policies. Once execution drifts off the demonstration manifold, these policies often continue producing locally plausible actions without recovering from the failure. Existing runtime monitors either require failure data, over-trigger under benign feature drift, or stop at failure detection without providing a recovery mechanism. We present Rewind-IL, a training-free online safeguard framework for generative action-chunked imitation policies. Rewind-IL combines a zero-shot failure detector based on Temporal Inter-chunk Discrepancy Estimate (TIDE), calibrated with split conformal prediction, with a state-respawning mechanism that returns the robot to a semantically verified safe intermediate state. Offline, a vision-language model identifies recovery checkpoints in demonstrations, and the frozen policy encoder is used to construct a compact checkpoint feature database. Online, Rewind-IL monitors self-consistency in overlapping action chunks, tracks similarity to the checkpoint library, and, upon failure, rewinds execution to the latest verified safe state before restarting inference from a clean policy state. Experiments on real-world and simulated long-horizon manipulation tasks, including transfer to flow-matching action-chunked policies, demonstrate that policy-internal consistency coupled with semantically grounded respawning offers a practical route to improved reliability in imitation learning. Supplemental materials are available at https://sjay05.github.io/rewind-il

Gehan Zheng, Sanjay Seenivasan, Matthew Johnson-Roberson +1

College of Connected Computing, Vanderbilt University, USA. · School of Computer Science, University of Waterloo, Canada. · School of Computer Science, The University of Sydney, Australia. +1

Robot Failure Detection Robot Failure Recovery Robotic Manipulation Robot Imitation Learning Anomaly Detection

Oct 20, 2025cs.RO

Video Replanning via Latent Embedding Refinement and Rejection-Based Sampling

Video planning has emerged as a flexible framework for robot manipulation, in which a generative model predicts a video of task completion, and a downstream module translates the predicted frames into actions. However, existing methods typically ignore information from past interactions, limiting their ability to adapt to latent physical properties that can only be revealed through trial and error, such as whether a door should be pushed or pulled, or how friction affects object dynamics. When a plan fails, these methods usually replan from scratch without leveraging the information revealed by the failure. To address this limitation, we introduce RELIC, REplanning with Latent embedding refInement and Candidate rejection, a video planning framework that adapts to hidden physical properties from test-time failures. RELIC optimizes a latent embedding that captures the environment's hidden physical properties from interaction videos and introduces a rejection-based sampling mechanism that filters out hypotheses inconsistent with prior failures. Across eight tasks in two simulation suites, RELIC consistently reduces the number of replanning steps required for success, and linear probes show that its embedding captures the hidden parameters from the interaction itself rather than from scene appearance. Across four challenging real-world robotic manipulation tasks involving hidden interaction modes, e.g., friction, center of mass, and object mass, RELIC raises the one-shot replanning success rate of a video planning baseline from 30.0% to 63.8% after a single physical interaction.

Po-Chen Ko, Yu Chan, Yu-Hsiang Fu +7

National Taiwan University · MIT CSAIL · Cornell University +1

Robot Failure Recovery Robotic Manipulation Robot Task Planning Rejection Sampling

Oct 2, 2025cs.RO

FailSafe: Reasoning and Recovery from Failures in Vision-Language-Action Models

Recent advances in robotic manipulation have integrated low-level robotic control into Vision-Language Models (VLMs), extending them into Vision-Language-Action (VLA) models. Although state-of-the-art VLAs achieve strong performance in downstream robotic applications, supported by large-scale crowd-sourced robot training data, they still inevitably encounter failures during execution. Enabling robots to reason and recover from unpredictable and abrupt failures remains a critical challenge. Existing robotic manipulation datasets, collected in either simulation or the real world, primarily provide only ground-truth trajectories, leaving robots unable to recover once failures occur. Moreover, the few datasets that address failure detection typically offer only textual explanations, which are difficult to utilize directly in VLA models. To address this gap, we introduce FailSafe, a novel failure generation and recovery system that automatically produces diverse failure cases paired with executable recovery actions. FailSafe can be easily adapted to a wide range of manipulation tasks in simulators with motion planning support, enabling scalable creation of failure-action data. To demonstrate its effectiveness, we fine-tune LLaVA-OneVision-7B (LLaVA-OV-7B) to build FailSafe-VLM. Experimental results show that FailSafe-VLM successfully helps robotic arms detect and recover from potential failures, improving the performance of three state-of-the-art VLA models (Pi-0-FAST, OpenVLA, OpenVLA-OFT) by up to 22.6% on average across several tasks in ManiSkill. Furthermore, FailSafe-VLM could generalize across different spatial configurations, camera viewpoints, object and robotic embodiments.

Zijun Lin, Jiafei Duan, Haoquan Fang +4

1Nanyang Technological University · Centre for Frontier AI Research, A*STAR · 3Allen Institute for AI +1

Robot Failure Recovery Synthetic Data Generation for Robotics Robotics Vision-Language-Action Models Robustness of VLA Models

Sep 17, 2025cs.RO

TransforMARS: Fault-Tolerant Self-Reconfiguration for Arbitrarily Shaped Modular Aerial Robot Systems

Modular Aerial Robot Systems (MARS) consist of multiple drone modules that are physically bound together to form a single structure for flight. Exploiting structural redundancy, MARS can be reconfigured into different formations to mitigate unit or rotor failures and maintain stable flight. Prior work on MARS self-reconfiguration has solely focused on maximizing controllability margins to tolerate a single rotor or unit fault for rectangular-shaped MARS. We propose TransforMARS, a general fault-tolerant reconfiguration framework that transforms arbitrarily shaped MARS under multiple rotor and unit faults while ensuring continuous in-air stability. Specifically, we develop algorithms to first identify and construct minimum controllable assemblies containing faulty units. We then plan feasible disassembly-assembly sequences to transport MARS units or subassemblies to form target configuration. Our approach enables more flexible and practical feasible reconfiguration. We validate TransforMARS in challenging arbitrarily shaped MARS configurations, demonstrating substantial improvements over prior works in both the capacity of handling diverse configurations and the number of faults tolerated. The videos and source code of this work are available at https://github.com/RuiHuangNUS/TransforMARS

Rui Huang, Zhiyu Gao, Siyu Tang +4

Department of Electrical and Computer Engineering, National University of Singapore, Singapore 117583 · Department of Mechanical Engineering, National University of Singapore, Singapore 117583

Multi-Robot Motion Planning Aerial Robotics Robot Failure Recovery Robotics Fault-Tolerant Control

May 18, 2025cs.RO

RoboFAC: A Comprehensive Framework for Robotic Failure Analysis and Correction

Vision-Language-Action (VLA) models have recently advanced robotic manipulation by translating natural-language instructions and visual observations into control actions. However, existing VLAs are primarily trained on successful expert demonstrations and lack structured supervision for failure diagnosis and recovery, limiting robustness in open-world scenarios. To address this limitation, we propose the Robotic Failure Analysis and Correction (RoboFAC) framework. We construct a large-scale failure-centric dataset comprising 9,440 erroneous manipulation trajectories and 78,623 QA pairs across 53 scenes in both simulation and real-world environments, with systematically categorized failure types. Leveraging this dataset, we develop a lightweight multimodal model specialized for task understanding, failure analysis, and failure correction, enabling efficient local deployment while remaining competitive with large proprietary models. Experimental results demonstrate that RoboFAC achieves a 34.1% higher failure analysis accuracy compared to GPT-4o. Furthermore, we integrated RoboFAC as an external supervisor in a real-world VLA control pipeline, yielding a 29.1% relative improvement across four tasks while significantly reducing latency relative to GPT-4o. These results demonstrate that RoboFAC enables systematic failure diagnosis and recovery, significantly enhancing VLA recovery capabilities. Our model and dataset are publicly available at https://github.com/MINT-SJTU/RoboFAC.

Zewei Ye, Weifeng Lu, Minghao Ye +4

School of AI, Shanghai Jiao Tong University · Harbin Institute of Technology, Shenzhen

Robot Failure Recovery Robustness of VLA Models Vision-Language-Action Models Fault Diagnosis

Jul 21, 2024cs.LG

Enhancing Hardware Fault Tolerance in Machines with Reinforcement Learning Policy Gradient Algorithms

Industry is moving toward autonomous, network-connected machines that detect and adapt to changing conditions, including hardware faults. Conventional fault-tolerant design duplicates hardware and reroutes control logic; reinforcement learning (RL) offers a learning-based alternative. This paper presents the first systematic comparison of two RL algorithms -- Proximal Policy Optimization (PPO) and Soft Actor-Critic (SAC) -- for integrating fault tolerance into control. Beyond algorithm choice, we investigate four knowledge-transfer strategies: retaining or discarding model parameters, and retaining or discarding storage contents. Performance is evaluated in two Gymnasium environments: Ant-v5 and FetchReachDense-v3. Results show rapid, fault-specific recovery with clear trade-offs. In Ant-v5, retaining PPO's parameters boosts early returns and remains the safest choice across all faults, while retaining SAC's parameters yields mixed outcomes. SAC's early performance further depends on whether the replay buffer is retained: beneficial when prior experiences match current dynamics, but harmful when they diverge. In FetchReachDense-v3, discarding both PPO's and SAC's parameters was most effective under sensor corruption. Across tasks, both algorithms recover near-normal performance within minutes in low-dimensional settings and within days in high-dimensional settings, highlighting a clear trade-off between adaptation speed and asymptotic performance. These findings demonstrate that RL can deliver robust fault tolerance and offer practical guidelines.

Sheila Schoepp, Mehran Taghian, Shotaro Miwa +3

Department of Computing Science, University of Alberta, 8900 114 St NW, Edmonton, Alberta, T6G 2S4, Canada · Advanced Technology R&D Center, Mitsubishi Electric Corporation, 8-1-1,Tsukaguchi-honmachi, Amagasaki-shi, Hyogo, 661-8661, Japan · Information Technology R&D Center, Mitsubishi Electric Corporation, 5-1-1, Ofuna, Kamakura-shi, Kanagawa, 247-8501, Japan +1

RL Control Reinforcement Learning Robot Failure Recovery Fault-Tolerant Control Proximal Policy Optimization Soft Actor-Critic+1