LEGO is a well-known platform for prototyping pixelized objects. However, robotic LEGO prototyping (i.e. manipulating LEGO bricks) is challenging due to the tight connections and accuracy requirement. This paper investigates safe and efficient robotic LEGO manipulation. In particular, this paper reduces the complexity of the manipulation by hardware-software co-design. An end-of-arm tool (EOAT) is designed, which reduces the problem dimension and allows large industrial robots to easily manipulate LEGO bricks. In addition, this paper uses evolution strategy to safely optimize the robot motion for LEGO manipulation. Experiments demonstrate that the EOAT performs reliably in manipulating LEGO bricks and the learning framework can effectively and safely improve the manipulation performance to a 100% success rate. The co-design is deployed to multiple robots (i.e. FANUC LR-mate 200id/7L and Yaskawa GP4) to demonstrate its generalizability and transferability. In the end, we show that the proposed solution enables sustainable robotic LEGO prototyping, in which the robot can repeatedly assemble and disassemble different prototypes.

Human-robot collaboration (HRC) is one key component to achieving flexible manufacturing to meet the different needs of customers. However, it is difficult to build intelligent robots that can proactively assist humans in a safe and efficient way due to several challenges. First, it is challenging to achieve efficient collaboration due to diverse human behaviors and data scarcity. Second, it is difficult to ensure interactive safety due to uncertainty in human behaviors. This paper presents an integrated framework for proactive HRC. A robust intention prediction module, which leverages prior task information and human-in-the-loop training, is learned to guide the robot for efficient collaboration. The proposed framework also uses robust safe control to ensure interactive safety under uncertainty. The developed framework is applied to a co-assembly task using a Kinova Gen3 robot. The experiment demonstrates that our solution is robust to environmental changes as well as different human preferences and behaviors. In addition, it improves task efficiency by approximately 15-20%. Moreover, the experiment demonstrates that our solution can guarantee interactive safety during proactive collaboration.

Deep reinforcement learning (RL) excels in various control tasks, yet the absence of safety guarantees hampers its real-world applicability. In particular, explorations during learning usually results in safety violations, while the RL agent learns from those mistakes. On the other hand, safe control techniques ensure persistent safety satisfaction but demand strong priors on system dynamics, which is usually hard to obtain in practice. To address these problems, we present Safe Set Guided State-wise Constrained Policy Optimization (S-3PO), a pioneering algorithm generating state-wise safe optimal policies with zero training violations, i.e., learning without mistakes. S-3PO first employs a safety-oriented monitor with black-box dynamics to ensure safe exploration. It then enforces a unique cost for the RL agent to converge to optimal behaviors within safety constraints. S-3PO outperforms existing methods in high-dimensional robotics tasks, managing state-wise constraints with zero training violation. This innovation marks a significant stride towards real-world safe RL deployment.

Tactile skins made from textiles enhance robot-human interaction by localizing contact points and measuring contact forces. This paper presents a solution for rapidly fabricating, calibrating, and deploying these skins on industrial robot arms. The novel automated skin calibration procedure maps skin locations to robot geometry and calibrates contact force. Through experiments on a FANUC LR Mate 200id/7L industrial robot, we demonstrate that tactile skins made from textiles can be effectively used for human-robot interaction in industrial environments, and can provide unique opportunities in robot control and learning, making them a promising technology for enhancing robot perception and interaction.

Following a leading vehicle is a daily but challenging task because it requires adapting to various traffic conditions and the leading vehicle's behaviors. However, the question `Does the following vehicle always actively react to the leading vehicle?' remains open. To seek the answer, we propose a novel metric to quantify the interaction intensity within the car-following pairs. The quantified interaction intensity enables us to recognize interactive and non-interactive car-following scenarios and derive corresponding policies for each scenario. Then, we develop an interaction-aware switching control framework with interactive and non-interactive policies, achieving a human-level car-following performance. The extensive simulations demonstrate that our interaction-aware switching control framework achieves improved control performance and data efficiency compared to the unified control strategies. Moreover, the experimental results reveal that human drivers would not always keep reacting to their leading vehicle but occasionally take safety-critical or intentional actions -- interaction matters but not always.

Reinforcement Learning (RL) algorithms have shown tremendous success in simulation environments, but their application to real-world problems faces significant challenges, with safety being a major concern. In particular, enforcing state-wise constraints is essential for many challenging tasks such as autonomous driving and robot manipulation. However, existing safe RL algorithms under the framework of Constrained Markov Decision Process (CMDP) do not consider state-wise constraints. To address this gap, we propose State-wise Constrained Policy Optimization (SCPO), the first general-purpose policy search algorithm for state-wise constrained reinforcement learning. SCPO provides guarantees for state-wise constraint satisfaction in expectation. In particular, we introduce the framework of Maximum Markov Decision Process, and prove that the worst-case safety violation is bounded under SCPO. We demonstrate the effectiveness of our approach on training neural network policies for extensive robot locomotion tasks, where the agent must satisfy a variety of state-wise safety constraints. Our results show that SCPO significantly outperforms existing methods and can handle state-wise constraints in high-dimensional robotics tasks.

Due to the trial-and-error nature, it is typically challenging to apply RL algorithms to safety-critical real-world applications, such as autonomous driving, human-robot interaction, robot manipulation, etc, where such errors are not tolerable. Recently, safe RL (i.e., constrained RL) has emerged rapidly in the literature, in which the agents explore the environment while satisfying constraints. Due to the diversity of algorithms and tasks, it remains difficult to compare existing safe RL algorithms. To fill that gap, we introduce GUARD, a Generalized Unified SAfe Reinforcement Learning Development Benchmark. GUARD has several advantages compared to existing benchmarks. First, GUARD is a generalized benchmark with a wide variety of RL agents, tasks, and safety constraint specifications. Second, GUARD comprehensively covers state-of-the-art safe RL algorithms with self-contained implementations. Third, GUARD is highly customizable in tasks and algorithms. We present a comparison of state-of-the-art safe RL algorithms in various task settings using GUARD and establish baselines that future work can build on.

Despite the tremendous success of Reinforcement Learning (RL) algorithms in simulation environments, applying RL to real-world applications still faces many challenges. A major concern is safety, in another word, constraint satisfaction. State-wise constraints are one of the most common constraints in real-world applications and one of the most challenging constraints in Safe RL. Enforcing state-wise constraints is necessary and essential to many challenging tasks such as autonomous driving, robot manipulation. This paper provides a comprehensive review of existing approaches that address state-wise constraints in RL. Under the framework of State-wise Constrained Markov Decision Process (SCMDP), we will discuss the connections, differences, and trade-offs of existing approaches in terms of (i) safety guarantee and scalability, (ii) safety and reward performance, and (iii) safety after convergence and during training. We also summarize limitations of current methods and discuss potential future directions.

For robots to be effectively deployed in novel environments and tasks, they must be able to understand the feedback expressed by humans during intervention. This can either correct undesirable behavior or indicate additional preferences. Existing methods either require repeated episodes of interactions or assume prior known reward features, which is data-inefficient and can hardly transfer to new tasks. We relax these assumptions by describing human tasks in terms of object-centric sub-tasks and interpreting physical interventions in relation to specific objects. Our method, Object Preference Adaptation (OPA), is composed of two key stages: 1) pre-training a base policy to produce a wide variety of behaviors, and 2) online-updating according to human feedback. The key to our fast, yet simple adaptation is that general interaction dynamics between agents and objects are fixed, and only object-specific preferences are updated. Our adaptation occurs online, requires only one human intervention (one-shot), and produces new behaviors never seen during training. Trained on cheap synthetic data instead of expensive human demonstrations, our policy correctly adapts to human perturbations on realistic tasks on a physical 7DOF robot. Videos, code, and supplementary material are provided.

This paper studies automatic prototyping using LEGO. To satisfy individual needs and self-sustainability, this paper presents a framework that learns the assembly and disassembly sequences from human demonstrations. In addition, a digital twin is developed to verify the correctness of robot learning before deploying to the real world. Moreover, an end-effector tool (EOT) is designed, which allows large industrial robots to easily manipulate LEGO bricks. The proposed system is deployed to a FANUC LR-mate 200id/7L robot. Experiments demonstrate that the proposed system can effectively learn the assembly and disassembly tasks from human demonstrations. And the learned tasks are realized by the FANUC robot.