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This research introduces a hybrid control framework that combines reinforcement learning for long-horizon decision-making with classical model-based controllers to safely maximize manipulator path length near kinematic boundaries. By leveraging conditional diffusion sampling for initial configurations and switching strategies based on joint limits, the method extends average rollout length by 27% on a 7-DoF robot across 10,000 tasks. The approach offers a practical solution for industrial applications like welding and coating where exploiting full workspace reachability is critical.
Extreme Motion Generation via Hybrid Null-Space Control for Straight-Line Path Following
arXiv:2606.03390v1 Announce Type: new Abstract: This work studies ``extreme motion generation'', which aims to maximize the Cartesian path length along a pre-defined trajectory within the manipulator's workspace. This objective is important in industry as long as path-following is fundamental to a large variety of tasks such as surface coating and welding. More critically, extreme motion enables a fixed-base manipulator to exploit the kinematic capability under limited reachability. However, such exploitation is challenging in practice, as the manipulator must actively avoid the safety boundary through execution, which is inherently a long-horizon problem. Accordingly, we claim that long-horizon decision-making should be delegated to a learning-based policy to maximize exploitation, while a classical model-based controller covers the near-boundary region, where the learning policy degrades sharply due to sparse data coverage. In detail, our proposed method is a step-level hybrid controller that switches between an RL-based and a model-based controller according to the normalized joint-limit distance. The initial joint configuration is sampled through conditional diffusion-based sampling, which improves the achievable path length based on the learned motion prior. We evaluate the proposed framework on 10,000 straight-line path-following tasks with a 7-DoF Franka FR3, extending the average rollout length by 27\% over the model-based baseline. Notably, certain tasks yield a pronounced extension toward the motion extreme, as reflected in the maximum improvement reported in the statistical results. The project website and related videos of this paper can be found at https://yuan-xinyi.github.io/extreme-motion-generation/.
Abstract:This work studies ``extreme motion generation'', which aims to maximize the Cartesian path length along a pre-defined trajectory within the manipulator's workspace. This objective is important in industry as long as path-following is fundamental to a large variety of tasks such as surface coating and welding. More critically, extreme motion enables a fixed-base manipulator to exploit the kinematic capability under limited reachability. However, such exploitation is challenging in practice, as the manipulator must actively avoid the safety boundary through execution, which is inherently a long-horizon problem. Accordingly, we claim that long-horizon decision-making should be delegated to a learning-based policy to maximize exploitation, while a classical model-based controller covers the near-boundary region, where the learning policy degrades sharply due to sparse data coverage. In detail, our proposed method is a step-level hybrid controller that switches between an RL-based and a model-based controller according to the normalized joint-limit distance. The initial joint configuration is sampled through conditional diffusion-based sampling, which improves the achievable path length based on the learned motion prior. We evaluate the proposed framework on 10,000 straight-line path-following tasks with a 7-DoF Franka FR3, extending the average rollout length by 27\% over the model-based baseline. Notably, certain tasks yield a pronounced extension toward the motion extreme, as reflected in the maximum improvement reported in the statistical results. The project website and related videos of this paper can be found at this https URL.
Robotics (cs.RO)
arXiv:2606.03390 [cs.RO]
(or arXiv:2606.03390v1 [cs.RO] for this version)
https://doi.org/10.48550/arXiv.2606.03390 Focus to learn more arXiv-issued DOI via DataCite (pending registration)
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