Robotic Anomaly Detection

Reliable real-time failure detection is critical for deploying learned robotic policies, yet defining failures explicitly is infeasible in open-world settings. This motivates failure detection from nominal demonstrations alone. Existing methods, however, struggle to balance robustness to benign variations with the ability to capture semantic and interaction-level errors. We introduce Robot-WATCHDOG, a self-supervised framework that models manipulation scenes as object-centric spatio-temporal graphs. Building on this representation, we investigate two complementary failure scores: Trajectory Projection and Correlation (TPC), a non-parametric measure of geometric deviation and relational consistency, and GnnT, a Graph Attention Network with a Transformer that predicts future object states. We evaluate both on a public benchmark and on a new dataset of semantically complex manipulation tasks, across six tasks and ten random seeds. Both scores outperform image-based failure detectors, particularly on semantic and interaction-level failures. TPC provides the strongest performance in AUPR and MCC on both dataset averages, with low variance across seeds. Qualitative results are made available at https://cea-list.github.io/Robot-WATCHDOG/.

Detecting failures during execution is essential for reliable robotic manipulation. Vision-language models (VLMs) can assess task outcomes semantically but add runtime computation, whereas out-of-distribution (OOD) detectors may respond to harmless scene variations rather than failure-relevant deviations. We introduce RAFAIL, a framework for detecting execution failures during robotic manipulation. RAFAIL identifies failures by detecting anomalies in task-relevant relationships between entities, such as a gripper and an object or an object and its target. By focusing OOD detection on relevant parts of the observation, RAFAIL reduces sensitivity to task-irrelevant scene variation. Offline, a VLM annotates successful demonstrations with task progress and relationship importance, which are used to learn point-cloud-based relationship representations without relying on policy-internal features. At runtime, relationship-specific OOD detectors evaluate these representations while relationship importance and task progress are predicted without VLM inference. RAFAIL requires no failure data and achieves 73.4% balanced accuracy across three real-world robotic manipulation tasks, outperforming the strongest evaluated OOD- and uncertainty-based baselines.

Video anomaly detection (VAD) is an actively studied task, having wide applications in typical scenarios such as public surveillance and road traffic safety. The task is also relevant for robotic arm interactions, where it has several downstream applications, including learning better interaction and manipulation abilities, triggering recovery procedures when anomalies occur, etc. Despite its relevance, the exploration of anomaly detection in robotic arm manipulation videos is limited by the low number of available resources. To this end, we introduce RoboVAD, a large-scale benchmark for video anomaly detection that comprises challenging cross-domain evaluation scenarios, where certain actions (tasks executed by a robotic arm) and anomaly types (mistakes that occur while performing certain tasks) remain unseen during training. RoboVAD is designed to benchmark VAD methods in realistic scenarios, where robotic arms can perform unforeseen tasks, and thereby encounter new anomaly types. We train and evaluate several state-of-the-art VAD methods, including a novel method specifically adapted for robotic arm manipulation. While the proposed method outperforms many state-of-the-art competitors, all methods remain below a micro-averaged frame-level AUC threshold of 70% in the most challenging evaluation setup, confirming the difficulty of the proposed benchmark. We publicly release our dataset and code at https://zenodo.org/records/22754659.

Self-driving laboratories increasingly rely on low-cost liquid handlers such as the Opentrons OT-2, which ship without the pressure-based aspiration monitoring of Hamilton or Tecan systems and are typically run open-loop. Two failure modes go undetected: protocols that are syntactically valid but violate assay-specific invariants (e.g., tip reuse between a PCR template and a no-template control), and physical execution failures (partial dispense, air bubbles, missing tips) at runtime. We present AEGIS, a two-layer guardian for both. Layer 1 pairs a curated machine-readable assay rule database with an LLM that reasons over OT-2 Python code, reaching an adjusted F1 of 0.97 on a 24-protocol benchmark across five assay families and beating rules-only and LLM-only ablations across five backends; a free open-weight model ties the best proprietary one, so no paid API is required. Layer 2 fits a PCA world model to YOLO-cropped four-frame pipette trajectories; under a leakage-free leave-one-plate-out evaluation it reaches average precision 0.89 and operating-point F1 0.71 (AUROC 0.80), a deployment-faithful number that matches the live demonstration, and we characterize the small-pipette (p20) resolution limit (F1 0.47). A live demonstration on a physical OT-2 (five replicates per condition) catches planted no-tip failures deterministically and partial dispense on coloured dyes, with an always-VLM self-vote gate lifting partial-dispense recall to 5/5; transparent water is a principled limit of any front-view-only monitor, which AEGIS surfaces as low-confidence VLM reasoning rather than a wrong verdict. Cascade triage holds VLM cost near $1.63 per plate versus$10.33 for an always-VLM baseline. AEGIS is open source and, to our knowledge, the first system to unify pre-flight assay-aware validation with runtime visual monitoring for an open-source liquid handler.

Industry automation is witnessing an evolution in robotics driven by both technological breakthroughs and societal changes: progress towards generalist robots, embodied and physical artificial intelligence (AI), and increasing labor shortage in manufacturing.An intelligent autonomous robot needs to not only act according to planned motions but also react to any unexpected events. In this study, we focus on such unexpected events in warehouses where robots are used for material handling. Specifically, we refer to any unexpected events as failures and develop methods to detect robot operations related failures. Rule-based detection methods may break since the form of failures could change due to the dynamic nature of both environments and tasks. We propose 'Fail-RAG', a Retrieval Augmented Generation (RAG)-based failure detection framework where failure images and context information are embedded and queried against a failure database by calculating their similarities. Vision-Language Models (VLMs) are further used to analyze failures and provide details by following our instruction template. We evaluated the performance of Fail-RAG by conducting both simulation and physical experiments using fixed robot arms and a mobile manipulator for multiple tasks that are common in warehouse automation. Fail-RAG achieved 25 percentage point higher failure detection accuracy on average across five types of robot operations compared to using off-the-shelf VLMs, indicating its effectiveness for real-world failure detection.

Learning-based manipulation policies have made substantial progress in real-world robot manipulation, particularly for short-horizon action generation. However, deployment in open workspaces remains fragile under unexpected local scene dynamics, such as moving objects, transient occlusions, or disturbances near the intended motion. Existing runtime monitors often rely on global observation anomalies, policy uncertainty, or frame-level visual changes, and struggle to distinguish task-relevant execution risk from benign visual variation. We introduce PATCH, an action-chunk-conditioned latent patch innovation monitor for deployment-time intervention. Given the active action chunk, PATCH defines a projected execution corridor, predicts latent patch evolution inside it, and accumulates persistent residuals unexplained by the robot's own motion. These residuals form a localized intervention signal that allows PATCH-Router to pause execution, select an available recovery source, and resume the original policy once localized innovation subsides. Experiments on real robot rollout data show that PATCH produces more stable and context-relevant triggers than competing runtime monitors. Real-robot deployment further demonstrates monitor-driven intervention and policy resumption for disturbance-aware manipulation. Project Page: https://yananzhou5555.github.io/PATCH/.

Generative robot policies fail unpredictably at deployment: they hesitate at critical moments, drift off-task, or commit to unrecoverable actions. Existing online failure detectors either require white-box access to policy internals or add runtime overhead through resampling and observation-side signals. Our empirical analysis shows that emitted action chunks themselves already carry strong predictive signal for impending failures in generative robot policies. Motivated by this observation, we introduce ActProbe, a lightweight, pure action-space detector that uses two compact signals available from a single forward pass: Temporal Consistency Error (TCE) between consecutive action chunks and Action Chunk Magnitude (ACM) of the current chunk. ActProbe maps these signals to per-step failure probabilities with a task-conditioned LSTM-MLP architecture. Across a diverse suite of generative robot policies and benchmarks, ActProbe raises alerts before failures become visually recognizable, improving the accuracy (F1)-timeliness Pareto frontier of failure detection by an average hypervolume gain of +12.7% over both internal- and external-feature baselines, with a +9.0% early-detection ROC-AUC lead on unseen tasks. ActProbe further transfers to deployment, predicting failures on unseen real-robot pick tasks and accelerating RL fine-tuning (PPO) with 2.9x fewer environment interactions.

Imitation learning (IL) policies in robotics deliver strong performance in controlled settings but remain brittle in real-world deployments: rare events such as hardware faults, defective parts, unexpected human actions, or any state that lies outside the training distribution can lead to failed executions. Vision-based Anomaly Detection (AD) methods emerged as an appropriate solution to detect these anomalous failure states but do not distinguish failures from benign deviations. We introduce FIDeL (Failure Identification in Demonstration Learning), a policy-independent failure detection module. Leveraging recent AD methods, FIDeL builds a compact representation of nominal demonstrations and aligns incoming observations via optimal transport matching to produce anomaly scores and heatmaps. Spatio-temporal thresholds are derived with an extension of conformal prediction, and a Vision-Language Model (VLM) performs semantic filtering to discriminate benign anomalies from genuine failures. We also introduce BotFails, a multimodal dataset of real-world tasks for failure detection in robotics. FIDeL consistently outperforms state-of-the-art baselines, yielding +5.30% percent AUROC in anomaly detection and +17.38% percent failure-detection accuracy on BotFails compared to existing methods.

Quality inspection in smart manufacturing requires identifying intrinsic material and surface properties beyond visible geometry, yet vision-only methods remain vulnerable to occlusion and reflection. We propose VitaTouch, a property-aware vision-tactile-language model for material-property inference and natural-language attribute description. VitaTouch uses modality-specific encoders and a dual Q-Former to extract language-relevant visual and tactile features, which are compressed into prefix tokens for a large language model. We align each modality with text and explicitly couple vision and touch through contrastive learning. We also construct VitaSet, a multimodal dataset with 186 objects, 52k images, and 5.1k human-verified instruction-answer pairs. VitaTouch achieves the best performance on HCT and the overall TVL benchmark, while remaining competitive on SSVTP. On VitaSet, it reaches 88.89% hardness accuracy, 75.13% roughness accuracy, and 54.81% descriptor recall; the material-description task further achieves a peak semantic similarity of 0.9009. With LoRA-based fine-tuning, VitaTouch attains 100.0%, 96.0%, and 92.0% accuracy for 2-, 3-, and 5-category defect recognition, respectively, and delivers 94.0% closed-loop recognition accuracy and 94.0% end-to-end sorting success in 100 laboratory robotic trials. More details are available at the project page: https://vitatouch.github.io/

Industrial deployment of robotic visual anomaly detection (VAD) is fundamentally constrained by passive perception under diverse 6-DoF pose configurations and unstable operating conditions such as illumination changes and shadows, where intrinsic semantic anomalies and physical disturbances coexist and interact. To overcome these limitations, a paradigm shift from passive feature learning to Active Canonicalization is proposed. PiCo (Pose-in-Condition Canonicalization) is introduced as a unified framework that actively projects observations onto a condition-invariant canonical manifold. PiCo operates through a cascaded mechanism. The first stage, Active Physical Canonicalization, enables a robotic agent to reorient objects in order to reduce geometric uncertainty at its source. The second stage, Neural Latent Canonicalization, adopts a three-stage denoising hierarchy consisting of photometric processing at the input level, latent refinement at the feature level, and contextual reasoning at the semantic level, progressively eliminating nuisance factors across representational scales. Extensive evaluations on the large-scale M2AD benchmark demonstrate the superiority of this paradigm. PiCo achieves a state-of-the-art 93.7% O-AUROC, representing a 3.7% improvement over prior methods in static settings, and attains 98.5% accuracy in active closed-loop scenarios. These results demonstrate that active manifold canonicalization is critical for robust embodied perception.

Vision-Language-Action (VLA) models have demonstrated strong potential for predicting semantic actions in navigation tasks, demonstrating the ability to reason over complex linguistic instructions and visual contexts. However, they are fundamentally hindered by visual-reasoning hallucinations that lead to trajectory deviations. Addressing this issue has conventionally required training external critic modules or relying on complex uncertainty heuristics. In this work, we discover that monitoring a few attention heads within a frozen VLA model can accurately detect path deviations without incurring additional computational overhead. We refer to these heads, which inherently capture the spatiotemporal causality between historical visual sequences and linguistic instructions, as Navigation Heads. Using these heads, we propose an intuitive, training-free anomaly-detection framework that monitors their signals to detect hallucinations in real time. Surprisingly, among over a thousand attention heads, a combination of just three is sufficient to achieve a 44.6 % deviation detection rate with a low false-positive rate of 11.7 %. Furthermore, upon detecting a deviation, we bypass the heavy VLA model and trigger a lightweight Reinforcement Learning (RL) policy to safely execute a shortest-path rollback. By integrating this entire detection-to-recovery pipeline onto a physical robot, we demonstrate its practical robustness. All source code will be publicly available.

Recent advances in Vision-Language-Action (VLA) models have enabled robots to execute increasingly complex tasks. However, VLA models trained through imitation learning struggle to operate reliably in dynamic environments and often fail under Out-of-Distribution (OOD) conditions. To address this issue, we propose Robot-Conditioned Normalizing Flow (RC-NF), a real-time monitoring model for robotic anomaly detection and intervention that ensures the robot's state and the object's motion trajectory align with the task. RC-NF decouples the processing of task-aware robot and object states within the normalizing flow. It requires only positive samples for unsupervised training and calculates accurate robotic anomaly scores during inference through the probability density function. We further present LIBERO-Anomaly-10, a benchmark comprising three categories of robotic anomalies for simulation evaluation. RC-NF achieves state-of-the-art performance across all anomaly types compared to previous methods in monitoring robotic tasks. Real-world experiments demonstrate that RC-NF operates as a plug-and-play module for VLA models (e.g., pi0), providing a real-time OOD signal that enables state-level rollback or task-level replanning when necessary, with a response latency under 100 ms. These results demonstrate that RC-NF noticeably enhances the robustness and adaptability of VLA-based robotic systems in dynamic environments.

As robotic systems execute increasingly difficult task sequences, so does the number of ways in which they can fail. Video Anomaly Detection (VAD) frameworks typically focus on singular, low-level kinematic or action failures, struggling to identify more complex temporal or spatial task violations, because they do not necessarily manifest as low-level execution errors. To address this problem, the main contribution of this paper is a new VAD-inspired architecture, TIMID, which is able to detect robot time-dependent mistakes when executing high-level tasks. Our architecture receives as inputs a video and prompts of the task and the potential mistake, and returns a frame-level prediction in the video of whether the mistake is present or not. By adopting a VAD formulation, the model can be trained with weak supervision, requiring only a single label per video. Additionally, to alleviate the problem of data scarcity of incorrect executions, we introduce a multi-robot simulation dataset with controlled temporal errors and real executions for zero-shot sim-to-real evaluation. Our experiments demonstrate that out-of-the-box VLMs lack the explicit temporal reasoning required for this task, whereas our framework successfully detects different types of temporal errors. Project: https://ropertunizar.github.io/TIMID/

Deploying visuomotor robots at scale is challenging due to the potential for anomalous failures to degrade performance, cause damage, or endanger human life. Bimanual manipulators are no exception; these robots have vast state spaces comprised of high-dimensional images and proprioceptive signals. Explicitly defining failure modes within such state spaces is infeasible. In this work, we overcome these challenges by training a probabilistic, history informed, world model within the compressed latent space of a pretrained vision foundation model (NVIDIA's Cosmos Tokenizer). The model outputs uncertainty estimates alongside its predictions that serve as non-conformity scores within a conformal prediction framework. We use these scores to develop a runtime monitor, correlating periods of high uncertainty with anomalous failures. To test these methods, we use the simulated Push-T environment and the Bimanual Cable Manipulation dataset, the latter of which we introduce in this work. This new dataset features trajectories with multiple synchronized camera views, proprioceptive signals, and annotated failures from a challenging data center maintenance task. We benchmark our methods against baselines from the anomaly detection and out-of-distribution detection literature, and show that our approach considerably outperforms statistical techniques. Furthermore, we show that our approach requires approximately one twentieth of the trainable parameters as the next-best learning-based approach, yet outperforms it by 3.8% in terms of failure detection rate, paving the way toward safely deploying manipulator robots in real-world environments where reliability is non-negotiable.

Autonomous inspection robots for monitoring industrial sites can reduce costs and risks associated with human-led inspection. However, accurate readings can be challenging due to occlusions, limited viewpoints, or unexpected environmental conditions. We propose a hybrid framework that combines supervised failure classification with anomaly detection, enabling classification of inspection tasks as a success, known failure, or anomaly (i.e., out-of-distribution) case. Our approach uses a world model backbone with compressed video inputs. This policy-agnostic, distribution-free framework determines classifications based on two decision functions set by conformal prediction (CP) thresholds before a human observer does. We evaluate the framework on gauge inspection feeds collected from office and industrial sites and demonstrate real-time deployment on a Boston Dynamics Spot. Experiments show over 90% accuracy in distinguishing between successes, failures, and OOD cases, with classifications occurring earlier than a human observer. These results highlight the potential for robust, anticipatory failure detection in autonomous inspection tasks or as a feedback signal for model training to assess and improve the quality of training data. Project website: https://autoinspection-classification.github.io

The safe deployment of autonomous systems in safety-critical settings requires a paradigm that combines human expertise with AI-driven analysis, especially when anomalies are unforeseen. We introduce AURA (Autonomous Resilience Agent), a collaborative framework for anomaly and fault diagnostics in robotics. AURA integrates large language models (LLMs), a high-fidelity digital twin (DT), and human-in-the-loop interaction to detect and respond to anomalous behavior in real time. The architecture uses two agents with clear roles: (i) a low-level State Anomaly Characterization Agent that monitors telemetry and converts signals into a structured natural-language problem description, and (ii) a high-level Diagnostic Reasoning Agent that conducts a knowledge-grounded dialogue with an operator to identify root causes, drawing on external sources. Human-validated diagnoses are then converted into new training examples that refine the low-level perceptual model. This feedback loop progressively distills expert knowledge into the AI, transforming it from a static tool into an adaptive partner. We describe the framework's operating principles and provide a concrete implementation, establishing a pattern for trustworthy, continually improving human-robot teams.