This paper addresses the challenges of Rhythmic Insertion Tasks (RIT), where a robot must repeatedly perform high-precision insertions, such as screwing a nut into a bolt with a wrench. The inherent difficulty of RIT lies in achieving millimeter-level accuracy and maintaining consistent performance over multiple repetitions, particularly when factors like nut rotation and friction introduce additional complexity. We propose a sim-to-real framework that integrates a reinforcement learning-based insertion policy with a failure forecasting module. By representing the wrench's pose in the nut's coordinate frame rather than the robot's frame, our approach significantly enhances sim-to-real transferability. The insertion policy, trained in simulation, leverages real-time 6D pose tracking to execute precise alignment, insertion, and rotation maneuvers. Simultaneously, a neural network predicts potential execution failures, triggering a simple recovery mechanism that lifts the wrench and retries the insertion. Extensive experiments in both simulated and real-world environments demonstrate that our method not only achieves a high one-time success rate but also robustly maintains performance over long-horizon repetitive tasks.

Industrial insertion tasks are often performed repetitively with parts that are subject to tight tolerances and prone to breakage. Learning an industrial insertion policy in real is challenging as the collision between the parts and the environment can cause slippage or breakage of the part. In this paper, we present a safe self-supervised method to learn a visuo-tactile insertion policy that is robust to grasp pose variations. The method reduces human input and collisions between the part and the receptacle. The method divides the insertion task into two phases. In the first align phase, a tactile-based grasp pose estimation model is learned to align the insertion part with the receptacle. In the second insert phase, a vision-based policy is learned to guide the part into the receptacle. The robot uses force-torque sensing to achieve a safe self-supervised data collection pipeline. Physical experiments on the USB insertion task from the NIST Assembly Taskboard suggest that the resulting policies can achieve 45/45 insertion successes on 45 different initial grasp poses, improving on two baselines: (1) a behavior cloning agent trained on 50 human insertion demonstrations (1/45) and (2) an online RL policy (TD3) trained in real (0/45).