docs(plan): add sim air insert ring bar implementation plan
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docs/superpowers/plans/2026-04-23-sim-air-insert-ring-bar.md
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docs/superpowers/plans/2026-04-23-sim-air-insert-ring-bar.md
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# sim_air_insert_ring_bar Implementation Plan
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> **For agentic workers:** REQUIRED SUB-SKILL: Use superpowers:subagent-driven-development (recommended) or superpowers:executing-plans to implement this plan task-by-task. Steps use checkbox (`- [ ]`) syntax for tracking.
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**Goal:** Add an independent dual-Diana MuJoCo task `sim_air_insert_ring_bar` with a square ring block, a square bar block, staged rewards, strict finite-geometry in-air insertion success detection, and a task-specific scripted policy.
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**Architecture:** Reuse the current dual-Diana EE-control stack and environment factory, but add a task-specific scene XML, robot asset entrypoint, sampling helpers, and a new task-specific environment module. Keep `sim_transfer` untouched while introducing pure-Python geometry helpers and focused tests so reward/success behavior can be regression tested without requiring a full MuJoCo rollout in every test.
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**Tech Stack:** Python, unittest, MuJoCo XML assets, existing dual-Diana environment classes, Hydra-compatible task naming/config patterns.
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---
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## File Structure / Responsibilities
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- **Create:** `roboimi/assets/models/manipulators/DianaMed/ring_bar_objects.xml`
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- Defines the rigid ring body and bar body, each with a free joint and stable box-based geoms.
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- **Create:** `roboimi/assets/models/manipulators/DianaMed/bi_diana_ring_bar_ee.xml`
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- Scene entrypoint that includes the shared world/table/robot assets plus the new object XML.
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- **Modify:** `roboimi/assets/robots/diana_med.py`
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- Add a task-specific robot asset class for the new scene XML without changing existing `BiDianaMed` behavior.
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- **Modify:** `roboimi/utils/act_ex_utils.py`
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- Add deterministic helpers to sample left/right planar placement regions for ring and bar objects.
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- **Modify:** `roboimi/utils/constants.py`
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- Register the new task name and default metadata.
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- **Create:** `roboimi/envs/double_air_insert_env.py`
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- New task-specific environment, finite-geometry success helpers, reset logic, reward logic, and task factory branch.
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- **Modify:** `roboimi/envs/double_pos_ctrl_env.py`
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- Route `make_sim_env()` to the new task-specific environment while keeping current `sim_transfer` logic unchanged.
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- **Create:** `roboimi/demos/diana_air_insert_policy.py`
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- Task-specific waypoint/open-loop scripted policy for grasp-lift-align-insert.
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- **Modify:** `roboimi/demos/vla_scripts/eval_vla.py`
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- Reset the new task with the correct sampled task state instead of assuming a single transfer box pose.
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- **Create:** `tests/test_air_insert_env.py`
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- Focused unit tests for sampling, reset helpers, reward progression, and strict success detection.
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- **Modify:** `tests/test_eval_vla_headless.py`
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- Add coverage that headless evaluation dispatches the correct reset sampler for the new task.
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- **Modify:** `tests/test_robot_asset_paths.py`
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- Verify the new robot asset class resolves its XML path correctly independent of cwd.
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---
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### Task 1: Add failing tests for task registration, samplers, and asset wiring
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**Files:**
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- Create: `tests/test_air_insert_env.py`
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- Modify: `tests/test_eval_vla_headless.py`
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- Modify: `tests/test_robot_asset_paths.py`
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- Modify: `roboimi/utils/act_ex_utils.py` (later in implementation)
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- Modify: `roboimi/utils/constants.py` (later in implementation)
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- Modify: `roboimi/assets/robots/diana_med.py` (later in implementation)
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- Modify: `roboimi/envs/double_pos_ctrl_env.py` (later in implementation)
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- [ ] **Step 1: Write failing tests for task config and sampling helpers**
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Add tests in `tests/test_air_insert_env.py` covering:
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- `SIM_TASK_CONFIGS['sim_air_insert_ring_bar']` exists
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- `sample_air_insert_ring_bar_pose()` (or equivalent helper) returns ring/bar positions with fixed z and correct left/right planar ranges
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- output structure is explicit and easy for reset/eval code to consume
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- [ ] **Step 2: Write failing tests for environment factory dispatch and robot asset resolution**
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Add tests covering:
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- `make_sim_env('sim_air_insert_ring_bar', headless=True)` dispatches to the new environment with rendering disabled
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- a new robot asset class resolves the new XML path independent of cwd, similar to the existing `BiDianaMed` test pattern
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- [ ] **Step 3: Write failing tests for eval reset helper dispatch**
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Extend `tests/test_eval_vla_headless.py` so headless eval can reset the new task using the new sampler instead of hard-coding `sample_transfer_pose()`.
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- [ ] **Step 4: Run the targeted tests to verify they fail for the expected missing-feature reasons**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env tests.test_eval_vla_headless tests.test_robot_asset_paths -v`
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Expected:
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- FAIL because the new task config/helper/class/dispatch branch does not exist yet
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- [ ] **Step 5: Implement the minimal production code to satisfy the new task registration and helper tests**
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Implement only enough to make the new tests pass:
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- add new task config entry
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- add the new placement sampler
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- add the new robot asset class
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- add the factory dispatch branch / headless wiring
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- update eval reset dispatch for the new task
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- [ ] **Step 6: Re-run the targeted tests to verify they pass**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env tests.test_eval_vla_headless tests.test_robot_asset_paths -v`
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Expected:
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- PASS for the new registration/sampler/dispatch/asset tests
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- [ ] **Step 7: Commit Task 1**
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Run:
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`git add tests/test_air_insert_env.py tests/test_eval_vla_headless.py tests/test_robot_asset_paths.py roboimi/utils/act_ex_utils.py roboimi/utils/constants.py roboimi/assets/robots/diana_med.py roboimi/envs/double_pos_ctrl_env.py roboimi/demos/vla_scripts/eval_vla.py && git commit -m "feat(env): register sim air insert ring bar task"`
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---
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### Task 2: Add the MuJoCo ring+bar scene assets and reset helpers
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**Files:**
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- Create: `roboimi/assets/models/manipulators/DianaMed/ring_bar_objects.xml`
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- Create: `roboimi/assets/models/manipulators/DianaMed/bi_diana_ring_bar_ee.xml`
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- Create or Modify: `roboimi/envs/double_air_insert_env.py`
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- Modify: `tests/test_air_insert_env.py`
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- [ ] **Step 1: Write failing tests for object reset helpers and scene-specific joint naming assumptions**
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In `tests/test_air_insert_env.py`, add unit tests for helper functions that:
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- write ring pose to `ring_block_joint`
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- write bar pose to `bar_block_joint`
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- read back task state in a stable structure
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Use fake `mj_data` objects so tests stay fast and deterministic.
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- [ ] **Step 2: Run the focused test slice and verify it fails**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- FAIL because reset/state helper functions and joint conventions are not implemented yet
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- [ ] **Step 3: Implement the scene XML files and reset/state helper code**
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Implement:
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- the object XML with one rigid ring body and one rigid bar body
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- the task scene XML entrypoint using the shared world/table/robot includes
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- reset helper(s) in `double_air_insert_env.py` that set qpos for both free joints with fixed quaternions
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- task-state accessor(s) returning both object poses in a stable structure
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- [ ] **Step 4: Re-run the focused test slice and verify it passes**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- PASS for reset/state helper tests
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- [ ] **Step 5: Commit Task 2**
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Run:
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`git add roboimi/assets/models/manipulators/DianaMed/ring_bar_objects.xml roboimi/assets/models/manipulators/DianaMed/bi_diana_ring_bar_ee.xml roboimi/envs/double_air_insert_env.py tests/test_air_insert_env.py && git commit -m "feat(scene): add ring and bar insertion scene assets"`
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---
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### Task 3: Implement strict reward and finite-geometry success detection
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**Files:**
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- Modify: `roboimi/envs/double_air_insert_env.py`
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- Modify: `tests/test_air_insert_env.py`
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- [ ] **Step 1: Write failing tests for reward stages and strict success detection**
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Add tests in `tests/test_air_insert_env.py` for:
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- left contact stage reward
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- right contact stage reward
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- ring lifted off table stage
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- bar lifted off table stage
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- positive success case where a finite bar truly passes through the aperture
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- negative case where the centerline would pass but the finite square body would clip
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- negative case where the bar has not crossed the ring thickness direction enough
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- negative case where one/both objects are still on the table
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Structure the tests around pure helper functions and light fake contact/state objects so the geometry logic is directly regression tested.
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- [ ] **Step 2: Run the focused tests and verify they fail for missing reward/success logic**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- FAIL because the staged reward and finite-geometry insertion logic are not implemented yet
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- [ ] **Step 3: Implement minimal strict success helpers and reward logic**
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Implement in `roboimi/envs/double_air_insert_env.py`:
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- pure helper(s) for transforming bar geometry into ring-local coordinates
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- finite-geometry insertion predicate (not centerline-only)
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- table-contact / airborne checks
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- staged reward function returning the highest achieved stage with `max_reward = 5`
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- [ ] **Step 4: Re-run the focused tests to verify the logic passes**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- PASS for reward and success-detection regression tests
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- [ ] **Step 5: Commit Task 3**
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Run:
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`git add roboimi/envs/double_air_insert_env.py tests/test_air_insert_env.py && git commit -m "feat(env): add strict air insertion reward and success logic"`
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---
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### Task 4: Add the scripted policy and integration smoke coverage
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**Files:**
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- Create: `roboimi/demos/diana_air_insert_policy.py`
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- Modify: `tests/test_air_insert_env.py`
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- Optionally Modify: `roboimi/demos/vla_scripts/eval_vla.py` (only if integration gaps remain after Task 1)
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- [ ] **Step 1: Write failing tests for scripted-policy action shape and basic generation**
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Add tests covering:
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- the new policy produces a 16D action
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- trajectory generation accepts sampled ring/bar state without error
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- the first action is a valid open-gripper safe pose command
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Keep the tests unit-level; do not require a full MuJoCo rollout for every assertion.
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- [ ] **Step 2: Write a small failing integration/smoke test for stepping the new task path**
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If practical with mocks/fakes, add a smoke test that verifies the policy can be used with the new environment interface without shape/dispatch mismatches.
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- [ ] **Step 3: Run the scripted-policy tests and verify they fail**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- FAIL because the new scripted policy does not exist yet
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- [ ] **Step 4: Implement the waypoint-based scripted policy**
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Implement a conservative open-loop policy with phases:
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- safe wait pose
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- above-target approach
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- descend + grasp
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- dual lift
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- airborne meeting alignment
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- bar push-through insertion
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Use fixed orientations for version 1 and follow the existing repository style from `diana_policy.py`.
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- [ ] **Step 5: Re-run the scripted-policy tests to verify they pass**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env -v`
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Expected:
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- PASS for scripted-policy tests
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- [ ] **Step 6: Run the combined verification suite for this feature**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env tests.test_eval_vla_headless tests.test_robot_asset_paths -v`
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Expected:
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- PASS with 0 failures
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- [ ] **Step 7: Commit Task 4**
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Run:
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`git add roboimi/demos/diana_air_insert_policy.py tests/test_air_insert_env.py tests/test_eval_vla_headless.py tests/test_robot_asset_paths.py roboimi/demos/vla_scripts/eval_vla.py && git commit -m "feat(policy): add scripted air insertion policy"`
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---
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### Task 5: Final verification and implementation review
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**Files:**
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- Review all files touched above
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- [ ] **Step 1: Run fresh end-to-end verification before claiming completion**
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Run:
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`/home/droid/.conda/envs/roboimi/bin/python -m unittest tests.test_air_insert_env tests.test_eval_vla_headless tests.test_robot_asset_paths -v`
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Expected:
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- PASS with 0 failures
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- [ ] **Step 2: Inspect git status and recent commits**
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Run:
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`git status --short && git log --oneline --decorate -n 8`
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Expected:
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- only intended feature files modified / committed
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- [ ] **Step 3: Request final code review for the completed feature**
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Use the requesting-code-review skill against the full diff from the feature branch starting point to current HEAD.
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- [ ] **Step 4: Address any review findings and re-run verification if code changes**
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If fixes are made, repeat the unittest command from Step 1.
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- [ ] **Step 5: Hand off using finishing-a-development-branch**
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After verification and review, use the finishing-a-development-branch skill to decide merge / PR / cleanup.
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