arXiv subjects

Satyandra K. Gupta

Publications and source records attributed to Satyandra K. Gupta.

17 recordsLinked to original sources

arXiv2026

Vision-Language Grounded Task-Context-Aware Imitation Learning for Robotic Disassembly

Real-world robotic disassembly requires long-horizon execution, where robots must perform ordered sequences of manipulation tasks across multiple parts within a single scene. Multiple valid task goals and diverse assembly configurations make it difficult for imitation policies to infer the intended skill from raw observations alone, particularly when training data cannot cover the combinatorial diversity of real-world configurations and part geometries. We show that incorporating task context through language alleviates these challenges by providing explicit structure for skill selection and associating language-specified tasks with their corresponding manipulation targets in the visual scene. The proposed framework combines hierarchical task selection with task-context-aware imitation learning to ground language instructions in spatial visual representations for robotic disassembly. The resulting framework generalizes across diverse connector geometries and assembly configurations without requiring explicit object annotations. Our method improves end-to-end task success by 35 percentage points over the baseline diffusion policy and by 75 percentage points over the previous task-context-aware baseline.

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arXiv2026

A Hierarchical Approach to Imitation Learning for Manipulation Tasks Requiring Time Varying Forces

Diffusion policies have shown strong performance in learning complex, multi-modal behaviors for robotic manipulation. However, their application to contact-rich disassembly tasks remains limited by a key trade-off: the iterative denoising process introduces inference latencies that makes high frequency control difficult, which is essential for realizing dynamic interactions such as chiseling and prying. Recent action-chunking techniques mitigate latency but use an open-loop execution window, rendering the system blind to rapid force transients caused by fracture events. To bridge this gap, we introduce the Diffusion Policy Augmented by Fast Trajectory Generation (DPA-FTG). Compared to recent visual-tactile approaches that focus on positional correction, DPA-FTG decouples low-frequency planning from high-frequency force regulation. At the high level ($5$ Hz), a conditional diffusion model predicts a sequence of latent parameters for selecting a strategy from a learned vocabulary of task primitives. At the low level ($60$ Hz), a lightweight, force-conditioned policy acts as a neural impedance controller, modulating execution in real-time to maintain contact stability. We validate our approach on a bimanual battery disassembly task involving the separation of a compliant sheet. Experimental evaluation demonstrates that DPA-FTG outperforms state-of-the-art baselines, including Reactive Diffusion Policy (RDP).

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arXiv2026

PREFAIL: Identifying Precursors to Failures in Robotic Lift-and-Place Tasks to Improve Task Execution Performance

Non-prehensile manipulation enables flexible material handling with part carriers, but friction-based support makes high-speed motions failure-prone, while slower operation increases cycle time. Proactive failure prediction is therefore essential for efficient and reliable performance, yet existing approaches remain limited by key constraints, including sensitivity to dynamic actions and high dependence on known policy structures. Furthermore, existing methods and datasets lack a precise characterization of the latest intervention time, leaving it unclear whether a detected failure can still be prevented through timely intervention. In this paper, we investigate lift-and-place tasks for non-prehensile material handling manipulation and propose a more effective approach to predicting precursors to failures (PREFAIL) by analyzing the relative motion of target objects with respect to the carrier. We further introduce a dataset that precisely identifies the latest intervention time for risky manipulations, enabling rigorous evaluation of whether a failure prediction is actionable. We validate our approach on both simulation and real-world datasets. Our experimental results demonstrate that PREFAIL substantially improves both the accuracy and timeliness of responses to failure precursors.

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arXiv2026

2026 Roadmap on Artificial Intelligence and Machine Learning for Smart Manufacturing

The evolution of artificial intelligence (AI) and machine learning (ML) is reshaping smart manufacturing by providing new capabilities for efficiency, adaptability, and autonomy across industrial value chains. However, the deployment of AI and ML in industrial settings still faces critical challenges, including the complexity of industrial big data, effective data management, integration with heterogeneous sensing and control systems, and the demand for trustworthy, explainable, and reliable operation in high-stakes industrial environments. In this roadmap, we present a comprehensive perspective on the foundations, applications, and emerging directions of AI and ML in smart manufacturing. It is structured in three parts. The first highlights the foundations and trends that frame the evolution of AI in smart manufacturing. The second focuses on key topics where AI is already enabling advances, including industrial big data analytics, advanced sensing and perception, autonomous systems, additive and laser-based manufacturing, digital twins, robotics, supply chain and logistics optimization, and sustainable manufacturing. The third section explores non-traditional ML approaches that are opening new frontiers, such as physics-informed AI, generative AI, semantic AI, advanced digital twins, explainable AI, RAMS, data-centric metrology, LLMs, and foundation models for highly connected and complex manufacturing systems. By identifying both opportunities and remaining barriers across these areas, this roadmap outlines the advances needed in methods, integration strategies, and industrial adoption. We hope this roadmap will serve as a guide for researchers, engineers, and practitioners to accelerate innovation, align academic and industrial priorities, and ensure that AI-driven smart manufacturing delivers reliable, sustainable, and scalable impact for the future of manufacturing ecosystems.

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arXiv2026

Preference-Conditioned Reinforcement Learning for Space-Time Efficient Online 3D Bin Packing

Robotic bin packing is widely deployed in warehouse automation, with current systems achieving robust performance through heuristic and learning-based strategies. These systems must balance compact placement with rapid execution, where selecting alternative items or reorienting them can improve space utilization but introduce additional time. We propose a selection-based formulation that explicitly reasons over this trade-off: at each step, the robot evaluates multiple candidate actions, weighing expected packing benefit against estimated operational time. This enables time-aware strategies that selectively accept increased operational time when it yields meaningful spatial improvements. Our method, STEP (Space-Time Efficient Packing), uses a preference-conditioned, Transformer-based reinforcement learning policy, and allows generalization across candidate set sizes and integration with standard placement modules. It achieves a 44% reduction in operational time without compromising packing density. Additional material is available at https://step-packing.github.io.

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arXiv2025

Accurate Pose Estimation Using Contact Manifold Sampling for Safe Peg-in-Hole Insertion of Complex Geometries

Robotic assembly of complex, non-convex geometries with tight clearances remains a challenging problem, demanding precise state estimation for successful insertion. In this work, we propose a novel framework that relies solely on contact states to estimate the full SE(3) pose of a peg relative to a hole. Our method constructs an online submanifold of contact states through primitive motions with just 6 seconds of online execution, subsequently mapping it to an offline contact manifold for precise pose estimation. We demonstrate that without such state estimation, robots risk jamming and excessive force application, potentially causing damage. We evaluate our approach on five industrially relevant, complex geometries with 0.1 to 1.0 mm clearances, achieving a 96.7% success rate - a 6x improvement over primitive-based insertion without state estimation. Additionally, we analyze insertion forces, and overall insertion times, showing our method significantly reduces the average wrench, enabling safer and more efficient assembly.

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arXiv2025

Automated Plan Refinement for Improving Efficiency of Robotic Layup of Composite Sheets

The automation of composite sheet layup is essential to meet the increasing demand for composite materials in various industries. However, draping plans for the robotic layup of composite sheets are not robust. A plan that works well under a certain condition does not work well in a different condition. Changes in operating conditions due to either changes in material properties or working environment may lead a draping plan to exhibit suboptimal performance. In this paper, we present a comprehensive framework aimed at refining plans based on the observed execution performance. Our framework prioritizes the minimization of uncompacted regions while simultaneously improving time efficiency. To achieve this, we integrate human expertise with data-driven decision-making to refine expert-crafted plans for diverse production environments. We conduct experiments to validate the effectiveness of our approach, revealing significant reductions in the number of corrective paths required compared to initial expert-crafted plans. Through a combination of empirical data analysis, action-effectiveness modeling, and search-based refinement, our system achieves superior time efficiency in robotic layup. Experimental results demonstrate the efficacy of our approach in optimizing the layup process, thereby advancing the state-of-the-art in composite manufacturing automation.

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arXiv2025

Kinematic Model Optimization via Differentiable Contact Manifold for In-Space Manipulation

Robotic manipulation in space is essential for emerging applications such as debris removal and in-space servicing, assembly, and manufacturing (ISAM). A key requirement for these tasks is the ability to perform precise, contact-rich manipulation under significant uncertainty. In particular, thermal-induced deformation of manipulator links and temperature-dependent encoder bias introduce kinematic parameter errors that significantly degrade end-effector accuracy. Traditional calibration techniques rely on external sensors or dedicated calibration procedures, which can be infeasible or risky in dynamic, space-based operational scenarios. This paper proposes a novel method for kinematic parameter estimation that only requires encoder measurements and binary contact detection. The approach focuses on estimating link thermal deformation strain and joint encoder biases by leveraging information of the contact manifold - the set of relative SE(3) poses at which contact between the manipulator and environment occurs. We present two core contributions: (1) a differentiable, learning-based model of the contact manifold, and (2) an optimization-based algorithm for estimating kinematic parameters from encoder measurements at contact instances. By enabling parameter estimation using only encoder measurements and contact detection, this method provides a robust, interpretable, and data-efficient solution for safe and accurate manipulation in the challenging conditions of space.

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arXiv2025

Learning the Contact Manifold for Accurate Pose Estimation During Peg-in-Hole Insertion of Complex Geometries

Contact-rich assembly of complex, non-convex parts with tight tolerances remains a formidable challenge. Purely model-based methods struggle with discontinuous contact dynamics, while model-free methods require vast data and often lack precision. In this work, we introduce a hybrid framework that uses only contact-state information between a complex peg and its mating hole to recover the full SE(3) pose during assembly. In under 10 seconds of online execution, a sequence of primitive probing motions constructs a local contact submanifold, which is then aligned to a precomputed offline contact manifold to yield sub-mm and sub-degree pose estimates. To eliminate costly k-NN searches, we train a lightweight network that projects sparse contact observations onto the contact manifold and is 95x faster and 18% more accurate. Our method, evaluated on three industrially relevant geometries with clearances of 0.1-1.0 mm, achieves a success rate of 93.3%, a 4.1x improvement compared to primitive-only strategies without state estimation.

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arXiv2025

Robotic Compliant Object Prying Using Diffusion Policy Guided by Vision and Force Observations

The growing adoption of batteries in the electric vehicle industry and various consumer products has created an urgent need for effective recycling solutions. These products often contain a mix of compliant and rigid components, making robotic disassembly a critical step toward achieving scalable recycling processes. Diffusion policy has emerged as a promising approach for learning low-level skills in robotics. To effectively apply diffusion policy to contact-rich tasks, incorporating force as feedback is essential. In this paper, we apply diffusion policy with vision and force in a compliant object prying task. However, when combining low-dimensional contact force with high-dimensional image, the force information may be diluted. To address this issue, we propose a method that effectively integrates force with image data for diffusion policy observations. We validate our approach on a battery prying task that demands high precision and multi-step execution. Our model achieves a 96\% success rate in diverse scenarios, marking a 57\% improvement over the vision-only baseline. Our method also demonstrates zero-shot transfer capability to handle unseen objects and battery types. Supplementary videos and implementation codes are available on our project website. https://rros-lab.github.io/diffusion-with-force.github.io/

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arXiv2024

Hierarchical Optimization-based Control for Whole-body Loco-manipulation of Heavy Objects

In recent years, the field of legged robotics has seen growing interest in enhancing the capabilities of these robots through the integration of articulated robotic arms. However, achieving successful loco-manipulation, especially involving interaction with heavy objects, is far from straightforward, as object manipulation can introduce substantial disturbances that impact the robot's locomotion. This paper presents a novel framework for legged loco-manipulation that considers whole-body coordination through a hierarchical optimization-based control framework. First, an online manipulation planner computes the manipulation forces and manipulated object task-based reference trajectory. Then, pose optimization aligns the robot's trajectory with kinematic constraints. The resultant robot reference trajectory is executed via a linear MPC controller incorporating the desired manipulation forces into its prediction model. Our approach has been validated in simulation and hardware experiments, highlighting the necessity of whole-body optimization compared to the baseline locomotion MPC when interacting with heavy objects. Experimental results with Unitree Aliengo, equipped with a custom-made robotic arm, showcase its ability to lift and carry an 8kg payload and manipulate doors.

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arXiv2022

Taxonomy of A Decision Support System for Adaptive Experimental Design in Field Robotics

Experimental design in field robotics is an adaptive human-in-the-loop decision-making process in which an experimenter learns about system performance and limitations through interactions with a robot in the form of constructed experiments. This can be challenging because of system complexity, the need to operate in unstructured environments, and the competing objectives of maximizing information gain while simultaneously minimizing experimental costs. Based on the successes in other domains, we propose the use of a Decision Support System (DSS) to amplify the human's decision-making abilities, overcome their inherent shortcomings, and enable principled decision-making in field experiments. In this work, we propose common terminology and a six-stage taxonomy of DSSs specifically for adaptive experimental design of more informative tests and reduced experimental costs. We construct and present our taxonomy using examples and trends from DSS literature, including works involving artificial intelligence and Intelligent DSSs. Finally, we identify critical technical gaps and opportunities for future research to direct the scientific community in the pursuit of next-generation DSSs for experimental design.

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arXiv2022

Contact Optimization for Non-Prehensile Loco-Manipulation via Hierarchical Model Predictive Control

Recent studies on quadruped robots have focused on either locomotion or mobile manipulation using a robotic arm. Legged robots can manipulate heavier and larger objects using non-prehensile manipulation primitives, such as planar pushing, to drive the object to the desired location. In this paper, we present a novel hierarchical model predictive control (MPC) for contact optimization of the manipulation task. Using two cascading MPCs, we split the loco-manipulation problem into two parts: the first to optimize both contact force and contact location between the robot and the object, and the second to regulate the desired interaction force through the robot locomotion. Our method is successfully validated in both simulation and hardware experiments. While the baseline locomotion MPC fails to follow the desired trajectory of the object, our proposed approach can effectively control both object's position and orientation with minimal tracking error. This capability also allows us to perform obstacle avoidance for both the robot and the object during the loco-manipulation task.

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arXiv2022

Towards Transferring Human Preferences from Canonical to Actual Assembly Tasks

To assist human users according to their individual preference in assembly tasks, robots typically require user demonstrations in the given task. However, providing demonstrations in actual assembly tasks can be tedious and time-consuming. Our thesis is that we can learn user preferences in assembly tasks from demonstrations in a representative canonical task. Inspired by previous work in economy of human movement, we propose to represent user preferences as a linear function of abstract task-agnostic features, such as movement and physical and mental effort required by the user. For each user, we learn their preference from demonstrations in a canonical task and use the learned preference to anticipate their actions in the actual assembly task without any user demonstrations in the actual task. We evaluate our proposed method in a model-airplane assembly study and show that preferences can be effectively transferred from canonical to actual assembly tasks, enabling robots to anticipate user actions.

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arXiv2021

Two-Stage Clustering of Human Preferences for Action Prediction in Assembly Tasks

To effectively assist human workers in assembly tasks a robot must proactively offer support by inferring their preferences in sequencing the task actions. Previous work has focused on learning the dominant preferences of human workers for simple tasks largely based on their intended goal. However, people may have preferences at different resolutions: they may share the same high-level preference for the order of the sub-tasks but differ in the sequence of individual actions. We propose a two-stage approach for learning and inferring the preferences of human operators based on the sequence of sub-tasks and actions. We conduct an IKEA assembly study and demonstrate how our approach is able to learn the dominant preferences in a complex task. We show that our approach improves the prediction of human actions through cross-validation. Lastly, we show that our two-stage approach improves the efficiency of task execution in an online experiment, and demonstrate its applicability in a real-world robot-assisted IKEA assembly.

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arXiv2020

Human-Supervised Semi-Autonomous Mobile Manipulators for Safely and Efficiently Executing Machine Tending Tasks

Mobile manipulators can be used for machine tending and material handling tasks in small volume manufacturing applications. These applications usually have semi-structured work environment. The use of a fully autonomous mobile manipulator for such applications can be risky, as an inaccurate model of the workspace may result in damage to expensive equipment. On the other hand, the use of a fully teleoperated mobile manipulator may require a significant amount of operator time. In this paper, a semi-autonomous mobile manipulator is developed for safely and efficiently carrying out machine tending tasks under human supervision. The robot is capable of generating motion plans from the high-level task description and presenting simulation results to the human for approval. The human operator can authorize the robot to execute the automatically generated plan or provide additional input to the planner to refine the plan. If the level of uncertainty in some parts of the workspace model is high, then the human can decide to perform teleoperation to safely execute the task. Our preliminary user trials show that non-expert operators can quickly learn to use the system and perform machine tending tasks.

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arXiv2019

An Alert-Generation Framework for Improving Resiliency in Human-Supervised, Multi-Agent Teams

Human-supervision in multi-agent teams is a critical requirement to ensure that the decision-maker's risk preferences are utilized to assign tasks to robots. In stressful complex missions that pose risk to human health and life, such as humanitarian-assistance and disaster-relief missions, human mistakes or delays in tasking robots can adversely affect the mission. To assist human decision making in such missions, we present an alert-generation framework capable of detecting various modes of potential failure or performance degradation. We demonstrate that our framework, based on state machine simulation and formal methods, offers probabilistic modeling to estimate the likelihood of unfavorable events. We introduce smart simulation that offers a computationally-efficient way of detecting low-probability situations compared to standard Monte-Carlo simulations. Moreover, for certain class of problems, our inference-based method can provide guarantees on correctly detecting task failures.

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