ROBOGATE: Adaptive Failure Discovery for Safe Robot Policy Deployment via Two-Stage Boundary-Focused Sampling
This addresses the need for safe and efficient pre-deployment validation of robot policies in industrial applications, though it is incremental as it builds on existing sampling and simulation methods.
The paper tackles the problem of efficiently discovering failure boundaries for robot policy deployment in industrial settings by introducing ROBOGATE, a framework that uses adaptive sampling to map failure zones, achieving an AUC of 0.780 and identifying universal danger zones across robot platforms.
Deploying learned robot manipulation policies in industrial settings requires rigorous pre-deployment validation, yet exhaustive testing across high-dimensional parameter spaces is intractable. We present ROBOGATE, a deployment risk management framework that combines physics-based simulation with a two-stage adaptive sampling strategy to efficiently discover failure boundaries in the operational parameter space. Stage 1 employs Latin Hypercube Sampling (LHS) across an 8-dimensional parameter space to establish a coarse failure landscape from 20,000 uniformly distributed experiments. Stage 2 applies boundary-focused sampling that concentrates 10,000 additional experiments in the 30-70% success rate transition zone, enabling precise failure boundary mapping. Using NVIDIA Isaac Sim with Newton physics, we evaluate a scripted pick-and-place controller on two robot embodiments -- Franka Panda (7-DOF) and UR5e (6-DOF) -- across 30,000 total experiments. Our logistic regression risk model achieves an AUC of 0.780 on the combined dataset (vs. 0.754 for Stage 1 alone), identifies a closed-form failure boundary equation, and reveals four universal danger zones affecting both robot platforms. We further demonstrate the framework on VLA (Vision-Language-Action) model evaluation, where Octo-Small achieves 0.0% success rate on 68 adversarial scenarios versus 100% for the scripted baseline -- a 100-point gap that underscores the challenge of deploying foundation models in industrial settings. ROBOGATE is open-source and runs on a single GPU workstation.