Vision-Language Models (VLMs) are increasingly used to evaluate robot manipulation outcomes, but existing benchmarks offer limited evidence of cross-domain generalization. We introduce FailBench, a benchmark for robot failure detection comprising 2,197 manipulation attempts across 14 public sources (12 real-world, 2 simulated). In FailBench, 75% of failures occur naturally, and six real-world sources come from non-failure-detection datasets. Evaluating 13 VLM-based detectors, we find the best model achieves only 0.77 mean balanced accuracy. Notably, models fine-tuned for failure detection consistently underperform general-purpose VLMs and their own pretrained baselines. Performance depends heavily on required visual evidence: models approach saturation when outcomes depend on observable object motion, but degrade to near-chance (<0.60 balanced accuracy) on contact-intensive assembly tasks. Error analysis reveals a systematic bias toward predicting success under ambiguous evidence, which persists even with increased reasoning effort. Finally, we show that input-level intervention--spatially localizing and cropping outcome-relevant regions--improves the top detector by 2.4 percentage points without extra training.
Diffusion-based vision-language-action (VLA) policies can generate plausible actions even when their predictions are weakly grounded in the visual and language evidence defining the task. We introduce GUARD, a test-time failure detection method that measures this grounding without modifying the pretrained policy. GUARD estimates the influence of token-indexed entries in the final vision-language model key-value (KV) cache, constructs counterfactual caches by ablating salient KV entries, and compares their denoising responses with the original conditioning. Based on the comparison, we derive GUARD diagnostic stream including sensitivity, attention entropy, modality bias, and grounding efficiency, which are calibrated online and processed by a lightweight temporal classifier. We evaluate GUARD under task-held-out splits across five policy-benchmark settings, using Pi0, SmolVLA, and Alpamayo-1.5 on LIBERO, SimplerEnv, MetaWorld, and PhysicalAI-AV. GUARD achieves the best ROC-AUC on four of five unseen-task settings and ranks second on the remaining setting, improving the average unseen-task ROC-AUC by 5.73 percentage points over the strongest competing runtime monitor while remaining within 0.19 points of the best seen-task average. These results show that directly probing action-head dependence on multimodal evidence provides a transferable failure signal across policies, tasks, embodiments, and domains.
Harshitha Rajaprakash, Aditeya Prajapati, Rong Xue +2cs.RO cs.CV
Vision-language-action policies often fail under deployment-time distribution shifts such as clutter, distractor objects, lighting changes, novel objects, altered initial states, and reworded instructions. Hidden-state-based risk probes combined with functional conformal prediction can detect rollout failures, but their reliability depends on calibration data matching deployment conditions. We introduce SAFECAST, which leverages contrast set perturbations to improve hidden-state probe training and calibration for deployment time shift. SAFECAST statistically significantly improves failure detection ROC-AUC scores over a state of the art baseline in both real-world DROID and LIBERO simulation experiments across multiple VLM backbones. We further find that SAFECAST benefits most when both visual and language contrast set perturbations are used to augment data, and that with contrast set perturbations, sim-to-real calibration leads to better probes than using real rollout data only.
Vision-language-action (VLA) policies achieve strong performance in robotic manipulation but remain vulnerable to runtime disturbances that break the temporal alignment among visual observations, robot states, and executed actions. We introduce ActFovea, a plug-and-play safeguarding framework that detects and mitigates such failures without retraining or modifying the underlying VLA policy. ActFovea uses robot kinematics, proprioceptive states, and recent actions to construct action-conditioned foveated regions that retain contact-relevant areas and predicted motion corridors while suppressing task-irrelevant visual content. It detects runtime risks by evaluating whether visual motion and observation freshness remain consistent with geometric, proprioceptive, and action transitions. For recoverable disturbances, ActFovea constructs disturbance-specific candidate observations and accepts a recovery only after verifying the resulting action chunk. When stale or replayed observations make reliable recovery impossible, it invokes a bounded safe-failure procedure. In closed-loop evaluations of $π_0$ across multiple LIBERO suites, ActFovea increases success under localized visual overlays from 49.3\% to 90.3\%, closing 93.7\% of the gap to clean performance. It further improves success under action drift and visual delay by 7.0 and 9.8 percentage points, respectively, while preserving clean-task performance. Under frozen-observation replay, ActFovea triggers timely safe failure in all trials, with no unprotected failures. These results demonstrate that spatiotemporal visual-action consistency provides an effective basis for runtime safeguarding of VLA policies.
Flow matching (FM) has become a popular action head paradigm for modern embodied models. However, as a conditional generative model, it does not explicitly expose its inherent uncertainty, producing faulty action chunks even when it misinterprets the scene or encounters out-of-distribution (OOD) inputs. Therefore, determining when an FM-generated action can be trusted is essential for safe deployment, yet existing uncertainty estimation methods on real-time control suffer from several issues: extra training budget, high computational overhead, and low generalization ability. In this work, we provide a geometric interpretation of FM uncertainty in the velocity field, showing that uncertainty manifests as deviation from an ideal affine-isotropic contraction field. Building on this observation, we introduce denoising acceleration ($\mathrm{accel}$), a highly-generalizable and cost-free uncertainty proxy that measures the bending of the denoising trajectory from a single forward pass, without additional model evaluations, training, or resampling. We theoretically and empirically demonstrate that $\mathrm{accel}$ is a faithful proxy for FM uncertainty and further test its utility in online failure detection. Results show that $\mathrm{accel}$ identifies failing rollouts well before termination, matching or even outperforming costly resampling- and training-based baselines across settings under realistic deployment budget. Code and demos available at: https://github.com/rrrrrrzy/fm-geometry.
Vision-language-action models (VLAs) achieve state-of-the-art performance on many robotic manipulation tasks, yet they can still behave unpredictably in out-of-distribution scenarios. Runtime failure detection is therefore essential for the safe real-world deployment of VLAs. However, existing task failure detectors require computationally expensive action sampling, are based on architectural assumptions that limit their applicability to VLAs, or need access to failure rollouts. We propose VLA-FAIL, a lightweight and broadly applicable failure detection framework for VLAs that combines two novel failure detectors with minimal overhead, without requiring failure data. The first, last-layer Mahalanobis distance (LLMD), detects out-of-distribution states by measuring token-wise deviations in last-layer features relative to the training data. The second, action chunk consistency (ACC), exploits the temporal overlap induced by receding-horizon control and detects failures when consecutive action chunks become inconsistent. To capture the trade-off between detection accuracy and detection latency, we introduce AUCPDT, a threshold-independent metric that jointly evaluates precision, recall, and detection time. Through extensive real-world and simulation experiments, we demonstrate that LLMD and ACC capture complementary failure modes whose combination enables reliable and early failure detection across diverse tasks, frequently outperforming significantly more expensive baseline methods.
Ralf Römer, Maximilian Seeliger, Saida Liu +5cs.RO cs.LG
Vision-language-action models (VLAs) combine vision-language backbones with expressive generative action heads trained via flow matching on large-scale robotic datasets. Despite their strong empirical performance in robotic manipulation, VLAs lack mechanisms to quantify confidence in their predictions and to detect when their actions may be unreliable. This presents a critical limitation for real-world deployment in non-stationary environments, where models inevitably encounter scenarios outside their pretraining distribution and may fail without warning. To address this, we derive an efficient method for quantifying epistemic uncertainty in flow-matching models by leveraging velocity-field disagreement (VFD) across a small ensemble. We successfully use this uncertainty estimate for failure detection during deployment and active fine-tuning of flow-based VLAs. To this end, we propose SAVE, a framework for uncertainty-guided active multitask fine-tuning that reduces the number of costly expert demonstrations required to adapt VLAs to new tasks. Through extensive experiments on the LIBERO benchmark, we demonstrate that VFD yields better-calibrated uncertainty estimates predictive of downstream performance, that VFD achieves strong performance in detecting failures, and that uncertainty-guided data acquisition with SAVE requires at least 22% fewer samples than baselines. In summary, our work shows that quantifying epistemic uncertainty in flow-based VLAs improves both failure awareness and adaptation. Project website: tum-lsy.github.io/uq_vla/.
Bingjia Huang, Xiangyu Li, Xiang Wang +7cs.RO cs.AI
Generative robot policies fail unpredictably at deployment: they hesitate at critical moments, drift off-task, or commit to unrecoverable actions. Existing online failure detectors either require white-box access to policy internals or add runtime overhead through resampling and observation-side signals. Our empirical analysis shows that emitted action chunks themselves already carry strong predictive signal for impending failures in generative robot policies. Motivated by this observation, we introduce ActProbe, a lightweight, pure action-space detector that uses two compact signals available from a single forward pass: Temporal Consistency Error (TCE) between consecutive action chunks and Action Chunk Magnitude (ACM) of the current chunk. ActProbe maps these signals to per-step failure probabilities with a task-conditioned LSTM-MLP architecture. Across a diverse suite of generative robot policies and benchmarks, ActProbe raises alerts before failures become visually recognizable, improving the accuracy (F1)-timeliness Pareto frontier of failure detection by an average hypervolume gain of +12.7% over both internal- and external-feature baselines, with a +9.0% early-detection ROC-AUC lead on unseen tasks. ActProbe further transfers to deployment, predicting failures on unseen real-robot pick tasks and accelerating RL fine-tuning (PPO) with 2.9x fewer environment interactions.
Long-horizon robot manipulation tends to fail gradually: one bad step degrades the state, and the policy spirals into a basin from which it cannot recover. The failure is often visible before it happens. We introduce AEGIS (Activation-probe Early-warning, Gated Inference Switching), a selective escalation method that uses a lightweight probe on a weak policy's frozen activations to detect high-risk steps while there is still time to act. When the probe flags a step, control switches to a stronger separate policy, but only for the steps that need it. On LIBERO-Spatial, AEGIS recovers 10.1% of the trajectories the weak policy alone loses, versus 4.6% for budget-matched blind escalation and 5.1% for a random-trigger placebo. These gains are significant under one-sided exact paired McNemar tests with Holm-Bonferroni adjustment over three pre-registered contrasts: +5.4pp over blind escalation, p=8.5e-6; +5.0pp over random triggering, p=1.0e-4; paired-trajectory bootstrap CIs exclude zero. AEGIS activates the stronger policy on only 38% of steps, so the lever is timing rather than compute. The probe clears its precondition with an early-window AUROC of 0.764, 95% CI [0.70, 0.84], read from the weak-policy path over the first 30% of trajectory steps before any handoff. We pre-register the full analysis plan, including a conditional recovered-task-rate estimand and explicit kill criteria, and confirm the result on 700 common-random-number episodes per arm, with nA-fail=646.