Robot Failure Recovery

This position paper looks briefly at the way we attempt to program robotic AI systems. Many AI systems are based on the idea of trying to improve the performance of one individual system to beyond so-called human baselines. However, these systems often look at one shot and one-way decisions, whereas the real world is more continuous and interactive. Humans, however, are often able to recover from and learn from errors - enabling a much higher rate of success. We look at the challenges of building a system that can detect/recover from its own errors, using the example of robotic nuclear gloveboxes as a use case to help illustrate examples. We then go on to talk about simple starting designs.

While robot action planning based on large language models (LLMs) has advanced remarkably, continuing a task after a physical action failure during execution remains a key challenge. For example, after failing to grasp an object, the robot may not notice that it has fallen off the table and keep trying to detect and pick it up, stalling the task. Existing approaches either rely on closed-loop autonomous re-planning, which fails when errors exceed the robot's capabilities, or on human intervention without updating the LLM's plan, hindering subsequent planning. We present a system for LLM-based robot action planning that integrates remote human intervention with feedback-based replanning. When the LLM detects an action failure, the robot requests remote assistance; an operator resolves the failure through teleoperation and reports the outcome in natural language, which is fed back to the LLM to update its plan so that the task can continue. We evaluated the proposed system on a real-world trash-collection task, comparing it with a fully autonomous method and a teleoperation-only baseline. The proposed system improves task progress over the autonomous method in this case study. For easy-to-retrieve trash, the gap from the teleoperation reference was small, while a larger gap remained for harder-to-retrieve trash. These results suggest that, in this case study, combining remote human intervention with feedback-based replanning was associated with continued task execution even in the face of otherwise unrecoverable failures. The project website is https://emergentsystemlabstudent.github.io/REPAIR/.

Unmanned aerial vehicles (UAVs) operating in cluttered environments require efficient and accurate impact modeling to maintain stability post collisions, however classical impulse contact models decouple the normal and tangential components. This letter presents a dual quaternion impulse reset map directly on the SE(3) manifold. By operating on the unified spatial twist (unified linear and angular velocities), the proposed formulation retains the cross-coupling between normal and tangential impulse components in a single closed-form expression, and recovers the classical decoupled Newton impulse model as a special case. A recovery controller is designed that couples linear and angular momentum to enforce kinetic energy dissipation across impacts. Hardware-in-the-loop benchmarks demonstrate a 24% reduction in execution latency compared to an optimized matrix-based implementation, and a 20% reduction relative to a position-plus-quaternion (PQ) formulation. MuJoCo simulations across Monte Carlo sweeps over impact angles and friction coefficients show a 50.8%-75.1% reduction in position root-mean-square error (RMSE) and a 68.7%-85% decrease in peak kinetic energy compared to published linear-admittance baselines.

While recent foundation models have significantly advanced robotic manipulation, these systems still struggle to autonomously recover from execution errors. Current failure-learning paradigms rely on either costly and unsafe real-world data collection or simulator-based perturbations, which introduce a severe sim-to-real gap. Furthermore, existing visual analyzers predominantly output coarse, binary diagnoses rather than the executable, trajectory-level corrections required for actual recovery. To bridge the gap between failure diagnosis and actionable recovery, we introduce Dream2Fix, a framework that synthesizes photorealistic, counterfactual failure rollouts directly from successful real-world demonstrations. By perturbing actions within a generative world model, Dream2Fix creates paired failure-correction data without relying on simulators. To ensure the generated data is physically viable for robot learning, we implement a structured verification mechanism that strictly filters rollouts for task validity, visual coherence, and kinematic safety. This engine produces a high-fidelity dataset of over 120k paired samples. Using this dataset, we fine-tune a vision-language model to jointly predict failure types and precise recovery trajectories, mapping visual anomalies directly to corrective actions. Extensive real-world robotic experiments show our approach achieves state-of-the-art correction accuracy, improving from 19.7% to 81.3% over prior baselines, and successfully enables zero-shot closed-loop failure recovery in physical deployments.

Measurement of task progress through explicit, actionable milestones is critical for robust robotic manipulation. This progress awareness enables a model to ground its current task status, anticipate verifiable intermediate states, and detect and recover from failures when progress stalls. To embody this capability, we introduce See, Plan, Rewind (SPR), a progress-aware vision-language-action framework that dynamically grounds language instructions into a sequence of spatial subgoals. SPR operates through a continuous core cycle, Seeing the current state and upcoming milestone, Planning a trajectory towards the next 2D waypoint, and Rewinding to a recoverable state upon failure by monitoring progress against the expected sequence. This closed-loop approach enables robust error correction without requiring additional training data or auxiliary models. Extensive experiments demonstrate the framework's effectiveness, generalization and robustness: SPR outperforms the MolmoAct baseline by 5% on the LIBERO benchmark. On the challenging LIBERO-Plus benchmark with unseen instructions and initial states, SPR achieves state-of-the-art robustness with the smallest performance drop, surpassing OpenVLA-OFT and UniVLA, demonstrating superior out-of-distribution robustness.

Robots fail, potentially leading to a loss in the robot's perceived reliability (PR), a measure correlated with trustworthiness. In this study we examine how various kinds of failures affect the PR of the robot differently, and how this measure recovers without explicit social repair actions by the robot. In a preregistered and controlled online video study, participants were asked to predict a robot's success in a pick-and-place task. We examined manipulation failures (slips), freezing (lapses), and three types of incorrect picked objects or place goals (mistakes). Participants were shown one of 11 videos -- one of five types of failure, one of five types of failure followed by a successful execution in the same video, or a successful execution video. This was followed by two additional successful execution videos. Participants bet money either on the robot or on a coin toss after each video. People's betting patterns along with a qualitative analysis of their survey responses highlight that mistakes are less damaging to PR than slips or lapses, and some mistakes are even perceived as successes. We also see that successes immediately following a failure have the same effect on PR as successes without a preceding failure. Finally, we show that successful executions recover PR after a failure. Our findings highlight which robot failures are in higher need of repair in a human-robot interaction, and how trust could be recovered by robot successes.

While robots deployed in real-world environments inevitably experience interaction failures, understanding how users respond through verbal and non-verbal behaviors remains under-explored in human-robot interaction (HRI). This gap is particularly significant in healthcare-inspired settings, where interaction failures can directly affect task performance and user trust. We present the Robot Failures in Medical HRI (RFM-HRI) Dataset, a multimodal dataset capturing dyadic interactions between humans and robots embodied in crash carts, where communication failures are systematically induced during item retrieval tasks. Through Wizard-of-Oz studies with 41 participants across laboratory and hospital settings, we recorded responses to four failure types (speech, timing, comprehension, and search) derived from three years of crash-cart robot interaction data. The dataset contains 214 interaction samples including facial action units, head pose, speech transcripts, and post-interaction self-reports. Our analysis shows that failures significantly degrade affective valence and reduce perceived control compared to successful interactions. Failures are strongly associated with confusion, annoyance, and frustration, while successful interactions are characterized by surprise, relief, and confidence in task completion. Emotional responses also evolve across repeated failures, with confusion decreasing and frustration increasing over time. This work contributes (1) a publicly available multimodal dataset (RFM-HRI), (2) analysis of user responses to different failure types and preferred recovery strategies, and (3) a crash-cart retrieval scenario enabling systematic comparison of recovery strategies with implications for safety-critical failure recovery. Our findings provide a foundation for failure detection and recovery methods in embodied HRI.

Vision-language model (VLM) shows promise for high-level planning in smart manufacturing, yet their deployment in dynamic workcells faces two critical challenges: (1) stateless operation, they cannot persistently track out-of-view states, causing world-state drift; and (2) opaque reasoning, failures are difficult to diagnose, leading to costly blind retries. This paper presents VLM-DEWM, a cognitive architecture that decouples VLM reasoning from world-state management through a persistent, queryable Dynamic External World Model (DEWM). Each VLM decision is structured into an Externalizable Reasoning Trace (ERT), comprising action proposal, world belief, and causal assumption, which is validated against DEWM before execution. When failures occur, discrepancy analysis between predicted and observed states enables targeted recovery instead of global replanning. We evaluate VLM-DEWM on multi-station assembly, large-scale facility exploration, and real-robot recovery under induced failures. Compared to baseline memory-augmented VLM systems, VLM DEWM improves state-tracking accuracy from 56% to 93%, increases recovery success rate from below 5% to 95%, and significantly reduces computational overhead through structured memory. These results establish VLM-DEWM as a verifiable and resilient solution for long-horizon robotic operations in dynamic manufacturing environments.

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.

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.

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

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.

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.