Impact of Markov Decision Process Design on Sim-to-Real Reinforcement Learning

Reinforcement Learning (RL) has demonstrated strong potential for industrial process control, yet policies trained in simulation often suffer from a significant sim-to-real gap when deployed on physical hardware. This work systematically analyzes how core Markov Decision Process (MDP) design choices -- state composition, target inclusion, reward formulation, termination criteria, and environment dynamics models -- affect this transfer. Using a color mixing task, we evaluate different MDP configurations and mixing dynamics across simulation and real-world experiments. We validate our findings on physical hardware, demonstrating that physics-based dynamics models achieve up to 50% real-world success under strict precision constraints where simplified models fail entirely. Our results provide practical MDP design guidelines for deploying RL in industrial process control.

The Crucial Role of Problem Formulation in Real-World Reinforcement Learning

Reinforcement Learning (RL) offers promising solutions for control tasks in industrial cyber-physical systems (ICPSs), yet its real-world adoption remains limited. This paper demonstrates how seemingly small but well-designed modifications to the RL problem formulation can substantially improve performance, stability, and sample efficiency. We identify and investigate key elements of RL problem formulation and show that these enhance both learning speed and final policy quality. Our experiments use a one-degree-of-freedom (1-DoF) helicopter testbed, the Quanser Aero~2, which features non-linear dynamics representative of many industrial settings. In simulation, the proposed problem design principles yield more reliable and efficient training, and we further validate these results by training the agent directly on physical hardware. The encouraging real-world outcomes highlight the potential of RL for ICPS, especially when careful attention is paid to the design principles of problem formulation. Overall, our study underscores the crucial role of thoughtful problem formulation in bridging the gap between RL research and the demands of real-world industrial systems.