Learning to Balance Motor Thermal Safety and Quadrupedal Locomotion Performance with Residual Policy

Motor thermal management is often overlooked in the context of electrically-actuated robots, particularly legged robots, but motor overheating is a key factor that limits long-duration locomotion especially under payload conditions. This paper integrates a whole-body thermal model of a quadruped robot into the reinforcement learning pipeline to update motor temperatures, and proposes a two-stage training framework for motor thermal management. In this framework, a nominal policy is first pre-trained as a locomotion baseline capable of traversing diverse terrains. A residual policy is then trained on top of the nominal policy to provide corrective actions based on the robot's thermal state, ensuring high performance under low-temperature conditions and preventing motor overheating under high-temperature conditions. Simulation results demonstrate that the proposed policy achieves an effective balance between motor thermal safety and locomotion performance. Real-world experiments on a Unitree A1 quadruped robot further validate the approach: under a 3 kg payload, the robot achieves stable locomotion across multiple terrains for over 13 minutes, while the nominal policy alone leads to motor overheating in about 5 minutes.

Learning Thermal-Aware Locomotion Policies for an Electrically-Actuated Quadruped Robot

Electrically-actuated quadrupedal robots possess high mobility on complex terrains, but their motors tend to accumulate heat under high-torque cyclic loads, potentially triggering overheat protection and limiting long-duration tasks. This work proposes a thermal-aware control method that incorporates motor temperatures into reinforcement learning locomotion policies and introduces thermal-constraint rewards to prevent temperature exceedance. Real-world experiments on the Unitree A1 demonstrate that, under a fixed 3 kg payload, the baseline policy triggers overheat protection and stops within approximately 7 minutes, whereas the proposed method can operate continuously for over 27 minutes without thermal interruptions while maintaining comparable command-tracking performance, thereby enhancing sustainable operational capability.