Removing a foot-spacing wall passed every simulated gate and made the feet collide on the real robot - nothing priced stance width in the two-foot phase, the policy narrowed to the simulator's self-collision floor, and real calibration offsets closed the last millimetres; the wall came back with a gate
removed-wall-returns-on-hardware.When a constraint is removed, name what will govern that quantity instead and add a gate for it; never let a simulator's collision floor be the margin, and when a gate is exceeded by a hair, record the exact numbers and hand the release decision to a person instead of quietly passing it.
Symptom
On the first real-robot try of oneleg_v0 (2026-09-16) the two feet collided; the user also judged the folded foot not high enough.
Context
The V0 reward table had dropped the feet_lateral_distance wall because it seemed to conflict with the hip adduction single support needs. In the two-foot command bucket no remaining term governed stance width, so the policy drifted narrower until the simulator's self-collision stopped it; the sim acceptance had no foot-spacing gate, so 40/40 said nothing about it. On the robot, calibration offsets consumed the margin.
Change
V0.1: the wall restored (-10, minimum 0.16 m), re-checked against measured numbers (a swing-phase lateral spacing of ~148 mm costs 0.12 per step, acceptable); fold weight 0.8 -> 2.0; a ninth gate: minimum foot spacing >= 100 mm and zero leg-contact frames. The removal was kept on record.
Outcome
oneleg_v0_1 (V0r2 model_2200) passed 39/40 with the spacing gate 40/40. The single miss (a 15.4 deg tilt transient against a < 15 deg limit during a side switch, steady 6.9 deg, everything else green) was recorded with its numbers and released for the user to overrule.
Mechanism
An unpriced degree of freedom drifts to wherever the simulator stops it; if that stop is the simulator's own collision model, the policy's margin on hardware is whatever the calibration error leaves.
Applies when
- dropping a reward term that looked redundant or conflicting
- hardware shows a failure no simulated gate measures
- a release candidate misses one gate row by a small amount
“V0 撤墙被真机证伪（2026-09-16）：双脚桶没有任何项管站宽，策略贴 sim 自碰撞底线收窄，真机标定偏差一吃**双脚相碰**。 … min ≥ 100 mm 且腿碰 0 帧（eval_straight 同判据）—— … V0 真机双脚相碰暴露 sim 门未看脚距的缺口 … L s2 标称 tilt 瞬态 15.4°（门限 <15, 超 0.4°, 稳态 6.9°, 该跑其余全绿）——换侧瞬态蹭线, 判定放行留档, 用户可否决。”