Set torque limits per joint from measured gait peaks - a uniform percentage is the wrong shape, and training must use the deployed numbers
torque-limit-shape-by-measured-peaks.Measure per-joint torque peaks in the actual gait and set each limit as measured-peak x margin capped at rating; then propagate the same numbers into training and add an automated deploy-time consistency check - never derate by a uniform percentage, never let training assume torque deployment will not grant.
Symptom
A uniform 50% torque derating (18/8.5/7) had piled safety margin on the joints that never use it while cutting the busiest joint below half its measured demand.
Context
Per-joint gait peaks were measured (walk_v5 at cmd 0.3/0.6): RS06 (hip_pitch/knee) uses 5.5-5.9 N*m = 15-16% of its 36 N*m rating - cutting it to 12 is a free safety win; RS02's ankle_pitch runs at 16.2 N*m = 95% of its 17 N*m rating - "它是速度的硬件瓶颈", no room to cut; RS00 measured 36-44%, capped at 11. The resulting shape 12/17/11 replaced the uniform percentage. Sweeps across several limit sets (rated / 50% / 14-17-11 / 12-17-11) produced identical speed, lift, and landing force - within this range the limits do not shape the gait; what matters is consistency: "关键是训练和硬件必须是同一个数", because the exporter fills effort_limit from tau_limit, and a policy trained at rated 36/17/14 "会假设有三倍力矩可用" while deployed at 12/17/11 (exactly the v5 cross-generation inconsistency later suspected in its wild kicking).
Change
robot.yaml tau_limit set to the measured-shape 12/17/11, firmware written to match, and train/isaac_values.py regenerated so training sees the same limits; the deploy tool self-checks limits against robot.yaml on every run.
Outcome
Free safety margin captured where demand is low, the real bottleneck joint left at rating, and the train/deploy torque worlds unified with an automated consistency check.
Mechanism
Torque demand is grossly unequal across joints in a gait (15% vs 95% of rating here); a uniform percentage misallocates the safety budget by construction. And since the trainer treats effort_limit as a plant truth, any train/deploy mismatch is an invisible plant gap of exactly the mismatch ratio.
Applies when
- choosing safety torque limits for a legged platform
- training-vs-deployment actuator limit audit
- one joint runs near rating while others idle
“曾用统一 50%(18/8.5/7)是错的形状: 把余量堆在用不到的 RS06 上, 却把 ankle_pitch 砍到需求的 52%。… RS02 在 0.6 m/s 已用到额定 95%, 它是速度的硬件瓶颈 … 实测多组限幅 … 完全一致 —— 限幅在这个范围对步态零影响, 关键是训练和硬件必须是同一个数。… 若训练仍按额定 36/17/14, 学出的策略会假设有三倍力矩可用。”