Contact Reduction with Bounded Stiffness for Robust Sim-to-Real Transfer of Robot Assembly

In sim-to-real Reinforcement Learning (RL), a policy is trained in a simulated environment and then deployed on the physical system. The main challenge of sim-to-real RL is to overcome the reality gap - the discrepancies between the real world and its simulated counterpart. Using generic geometric representations, such as convex decomposition, triangular mesh, signed distance field can improve simulation fidelity, and thus potentially narrow the reality gap. Common to these approaches is that many contact points are generated for geometrically-complex objects, which slows down simulation and may cause numerical instability. Contact reduction methods address these issues by limiting the number of contact points, but the validity of these methods for sim-to-real RL has not been confirmed. In this paper, we present a contact reduction method with bounded stiffness to improve the simulation accuracy. Our experiments show that the proposed method critically enables training RL policy for a tight-clearance double pin insertion task and successfully deploying the policy on a rigid, position-controlled physical robot.