Yang Gao
Publications
When Does Legacy Data Start to Help? Emergent Transfer in Cross-Configuration Robot Learning
Robotic hardware evolves over time, but demonstration data is often tied to a specific sensor and actuator configuration. This raises a practical and underexplored question: when does legacy data begin to benefit an upgraded robot? We study this question on a wheeled humanoid platform across two hardware generations, where both the camera and gripper are changed while the overall morphology remains fixed. Contrary to the common assumption that more cross-configuration data is always helpful, we observe a grokking-like transition: legacy data remains ineffective until the upgraded configuration acquires a minimum level of task competence, after which co-training gains rise sharply before diminishing near saturation. We hypothesize that this task-dependent transition is governed by a transfer threshold and characterize the resulting three-phase pattern. Across real-robot manipulation tasks, we observe all three phases: no measurable benefit at low competence ($10.0\% \rightarrow 10.0\%$), a sharp gain after crossing the threshold ($23.3\% \rightarrow 86.7\%$ on flower insertion), and diminishing returns at high competence ($85.0\% \rightarrow 93.3\%$ on pen insertion). We provide a theoretical account based on gradient alignment and residual policy uncertainty, and derive a phase-aware rule for deciding when to collect more new-hardware data and when to reuse legacy demonstrations. We further validate this three-phase pattern on a mobile dual-arm watering task, with results consistent with our predictions.
A Practical Recipe Towards Improving Sim-and-Real Correlation for VLA Evaluation
Simulation has become an essential tool for evaluating and improving vision-language-action (VLA) policies, offering scalable, reproducible, and controllable alternatives to costly real-world robot evaluation. Recent simulation benchmarks have made substantial progress on realism and diversity, yet these platforms have not been widely adopted as reliable proxies for real-world policy evaluation. In this work, we investigate this issue through the lens of sim-and-real correlation. We conduct a systematic study across multiple simulation platforms, VLA policies, tasks, and perturbation factors, measuring whether simulated evaluation preserves real-world conclusions in terms of policy ranking consistency, performance correlation, and perturbation-wise failure patterns. This analysis allows us to characterize the limitations of existing simulators and identify what kinds of simulation signals are more aligned with real-world deployment. We further examine how users should exploit simulation for policy improvement, including when simulator-based finetuning is beneficial and how the amount of post-training data affects sim-and-real alignment. Overall, our work provides a unified framework for measuring, interpreting, and improving the usefulness of simulation for VLA policies, offering guidance both for simulator designers and for practitioners who use simulation as part of the policy development pipeline.