Navigation Primitives — Shared Substrate

Foundation layer for mobile robot navigation. Consumed by:

• isaac-sim-robot-navigation: runtime navigation in custom scripts (RL policy, physics-vs-baked, GPU OOM).
• mobility-gen: two-phase MobilityGen SDG (record -> replay+render).
• occupancy-map: produces the map.yaml consumed here.

Read this first for any mobile-robot work, then jump to the specialization.

Shared NVIDIA APIs

OccupancyMap.from_ros_yaml(path) loads a YAML+PNG pair (produced by occupancy-map). Both isaac-sim-robot-navigation and mobility-gen consume this same format.

Robot Footprints & Z-Offsets — Derived at Runtime

Do not hardcode footprints. Walk the articulation's collider prims and union their world-space AABBs. This handles every robot (Spot, Carter, VSVXL, Jetbot, Kaya, H1, custom) and stays correct when assets change.

import isaacsim.core.experimental.utils.bounds as bounds_utils
from pxr import Usd, UsdPhysics
import numpy as np

def compute_robot_footprint(stage: Usd.Stage, robot_root: str) -> dict:
    """Return footprint dims + Z-offset + inscribed/circumscribed radii.

    Uses prims tagged with UsdPhysics.CollisionAPI under `robot_root`. Falls back
    to UsdGeom.Imageable if no colliders are authored.
    """
    collider_paths = []
    for prim in Usd.PrimRange(stage.GetPrimAtPath(robot_root)):
        if prim.HasAPI(UsdPhysics.CollisionAPI):
            collider_paths.append(prim.GetPath())
    if not collider_paths:
        collider_paths = [stage.GetPrimAtPath(robot_root).GetPath()]

    aabb = bounds_utils.compute_combined_aabb(collider_paths)  # [xmin,ymin,zmin, xmax,ymax,zmax]
    mn, mx = aabb[:3], aabb[3:]
    size = mx - mn

    origin_z = stage.GetPrimAtPath(robot_root).GetAttribute("xformOp:translate").Get()[2]
    z_offset = max(0.0, origin_z - mn[2])  # how far origin sits above lowest collider

    half_w, half_d = size[0] / 2.0, size[1] / 2.0
    return {
        "size": tuple(size),                       # full footprint extents (m)
        "z_offset": float(z_offset),               # origin → lowest collider (m)
        "inscribed_radius":  float(min(half_w, half_d)),  # safe for ANY yaw
        "circumscribed_radius": float(np.hypot(half_w, half_d)),  # worst-case yaw
        "aabb_min": tuple(mn),
        "aabb_max": tuple(mx),
    }

Use inscribed_radius when the robot can rotate freely in place (over-conservative, zero clip). Use circumscribed_radius only when you require zero false negatives. For non-circular robots (Spot, VSVXL), prefer the oriented-footprint check below over a single radius.

Always spawn the robot at z = ground + z_offset. Missing the Z-offset is the #1 cause of "robot falls through the floor" or "feet pop above ground" bugs.

Reference Values (sanity check only)

If your compute_robot_footprint output is far from these, your collider authoring or scene units are wrong:

Occupancy Map from USD (Direct Projection)

Use when you need a runtime omap and don't already have a map.yaml. For the canonical map.yaml workflow consumed by MobilityGen, use occupancy-map instead.

from pxr import Usd, UsdGeom, Gf
import numpy as np

stage = Usd.Stage.Open(stage_path)
bbox_cache = UsdGeom.BBoxCache(Usd.TimeCode.Default(), [UsdGeom.Tokens.default_])

RESOLUTION = 0.25  # meters per cell
X_RANGE = (-15, 175)
Y_RANGE = (-25, 155)
Z_CUTOFF = 4.5  # ignore obstacles above this height
# Robot dims come from compute_robot_footprint(stage, "/World/Robot"); see above.

grid_w = int((X_RANGE[1] - X_RANGE[0]) / RESOLUTION)
grid_h = int((Y_RANGE[1] - Y_RANGE[0]) / RESOLUTION)
grid = np.zeros((grid_h, grid_w), dtype=np.uint8)  # 0=free, 255=occupied

for prim in Usd.PrimRange(stage.GetPrimAtPath("/World")):
    bb = bbox_cache.ComputeWorldBound(prim)
    r = bb.ComputeAlignedRange()
    if r.IsEmpty(): continue
    mn, mx = r.GetMin(), r.GetMax()
    if mn[2] > Z_CUTOFF: continue
    x0 = max(0, int((mn[0] - X_RANGE[0]) / RESOLUTION))
    x1 = min(grid_w, int((mx[0] - X_RANGE[0]) / RESOLUTION))
    y0 = max(0, int((mn[1] - Y_RANGE[0]) / RESOLUTION))
    y1 = min(grid_h, int((mx[1] - Y_RANGE[0]) / RESOLUTION))
    grid[y0:y1, x0:x1] = 255

Obstacle Filtering (CRITICAL — learned 2026-03-13)

Two strategies, in order of preference:

A. Collider-driven (preferred when assets have authored colliders). Iterate only prims with UsdPhysics.CollisionAPI. This already excludes visual-only geometry (signage, decals, light cones, debug arrows) without a filter list.

from pxr import UsdPhysics
for prim in Usd.PrimRange(stage.GetPrimAtPath("/World")):
    if not prim.HasAPI(UsdPhysics.CollisionAPI):
        continue
    enabled = prim.GetAttribute("physics:collisionEnabled")
    if enabled and enabled.Get() is False:
        continue
    # rasterize this prim's AABB into the grid

B. Visual-bbox + filter list (fallback for scenes without colliders). Naive bbox projection fills the grid with shell, zones, signage. Filter aggressively:

SKIP_SCOPES = {"GroundPlane", "Looks", "Lighting", "Render", "PushGraph",
               "DomeLight", "DemoCamera", "Spot_01", "Spot_02", "Obstacles_Anim"}
SKIP_PREFIXES = ("Floor", "FL_", "FR_", "Exit_", "Hum", "SM_Deluxe")
SKIP_CHILDREN = ("sm_warehouse_mega", "Zones", "signage")

Geometric filters (apply after either strategy):

• Skip area > 3000 m² (shell, zone assemblies)
• Skip height < 0.1 m (floor markings, safety tape)
• Skip Z_min > 3.6 m (ceiling-only objects, ≈ 3× robot height)
• Skip Z_max < fp["z_offset"] + 0.05 m (anything the robot can drive over)

Result on V4 KION: 244 real obstacles (vs 5000+ before filtering), 70% free space.

Buffer Sizing — Derived from Footprint

The buffer is circumscribed_radius + safety_margin, not a magic constant. Empirical safety_margin defaults (validated 2026-03-15):

fp = compute_robot_footprint(stage, "/World/Robot")
buffer_m = fp["circumscribed_radius"] + 0.30  # aisle default
buffer_cells = int(round(buffer_m / RESOLUTION))

For Spot (circumscribed_radius ≈ 0.58 m) this yields ~0.88–1.08 m, not the legacy 1.5 m blanket value. The legacy value was conservatively tuned against a circular proxy; with the oriented-footprint check (below) you recover the extra ~0.5 m of navigable space.

A* Path Planning

Erode by inscribed_radius (fast, conservative). Then validate the smoothed path with an oriented-footprint collision check, which recovers the navigable space the inscribed-radius erosion threw away.

from scipy.ndimage import binary_erosion
import numpy as np

fp = compute_robot_footprint(stage, "/World/Robot")
kernel_r = int(fp["inscribed_radius"] / RESOLUTION)
kernel = np.zeros((2*kernel_r+1, 2*kernel_r+1), dtype=bool)
for dy in range(-kernel_r, kernel_r+1):
    for dx in range(-kernel_r, kernel_r+1):
        if dx*dx + dy*dy <= kernel_r*kernel_r:
            kernel[dy+kernel_r, dx+kernel_r] = True

navigable = (grid == 0)
eroded = binary_erosion(navigable, structure=kernel)
# Standard A* over `eroded` (heapq-based)

Oriented-Footprint Collision Check (recommended for non-circular robots)

Drives the same PhysX query the simulator uses. Works in two modes:

1. Against PhysX scene (after SimulationManager.initialize()): use get_physx_scene_query_interface().overlap_box. Returns hit count; >0 means clip.

import carb
from omni.physx import get_physx_scene_query_interface
from pxr import Gf

def footprint_clips(x: float, y: float, yaw: float, fp: dict, z_query: float = 0.2) -> bool:
    # half-extents of the robot footprint
    half = carb.Float3(fp["size"][0] / 2, fp["size"][1] / 2, fp["size"][2] / 2)
    origin = carb.Float3(x, y, z_query + fp["size"][2] / 2)
    # quaternion (x, y, z, w) for yaw about Z
    rot = Gf.Rotation(Gf.Vec3d(0, 0, 1), np.degrees(yaw)).GetQuat()
    quat = carb.Float4(*rot.GetImaginary(), rot.GetReal())
    hits = get_physx_scene_query_interface().overlap_box(
        half, origin, quat, lambda h: True, anyHit=True,  # early-exit on first hit
    )
    return hits > 0

2. Against the rasterized omap (no PhysX needed): stamp the rotated rectangle onto the obstacle grid and AND with the occupied mask.

import cv2

def footprint_clips_grid(px: int, py: int, yaw: float, fp: dict, grid: np.ndarray) -> bool:
    w_cells = fp["size"][0] / RESOLUTION
    h_cells = fp["size"][1] / RESOLUTION
    rect = ((px, py), (w_cells, h_cells), np.degrees(yaw))
    pts = cv2.boxPoints(rect).astype(np.int32)
    mask = np.zeros_like(grid, dtype=np.uint8)
    cv2.fillPoly(mask, [pts], 1)
    return bool(np.any((grid > 0) & (mask > 0)))

Validation Pipeline (MANDATORY)

1. compute_robot_footprint(stage, robot_root) — get size, z_offset, radii.
2. Rasterize obstacles onto grid (0.25 m resolution typical).
3. Binary erode with circular kernel of radius = inscribed_radius / resolution.
4. A* pathfind on eroded grid.
5. Catmull-Rom smooth the raw path; assign yaw = atan2(dy, dx) along the curve.
6. For every smoothed waypoint, run footprint_clips_grid(px, py, yaw, fp, grid) (or footprint_clips(...) against PhysX). Reject the path on any hit.
7. If a single waypoint fails, snap to the nearest navigable cell and re-validate. If multiple fail, the inscribed-radius A* path is fundamentally bad — re-plan with a larger erosion kernel (circumscribed_radius).

Skipping steps 6–7 produces paths that look fine on the omap but clip walls in render — especially on rectangular robots (Spot, VSVXL) cornering through aisles.

Differential Drive Kinematics

# Wheel velocities from body twist
vL = (vx - omega * track_w / 2) / wheel_r
vR = (vx + omega * track_w / 2) / wheel_r

PD steering (validated on Nova Carter / VSVXL):

• KP=2.5, KD=1.2, MAX_W=1.5 rad/s
• Waypoint tolerance: 4.0m
• Speed reduction near waypoints and during large heading errors
• Out-of-bounds: |Z| > 50 or |X|/|Y| > 500 → mark dead

VSVXL validated parameters (LLM Advisor Grok-4, 2026-03-15):

• ω = v / r (0.15m wheels → 10 rad/s for 1.5 m/s)
• Physics: dt=1/120s, substeps=4 (effective 480Hz)
• PID heading: Kp=2.0, Ki=0.1, Kd=0.5, max angular 1.0 rad/s
• Aisle speed: 0.8 m/s; corridor speed: 1.5 m/s
• Corridor buffer: 0.5m; aisle buffer: 0.2m + reduced speed

Holonomic / Mecanum (Kaya, AMR)

Use HolonomicController with HolonomicRobotUsdSetup to extract wheel positions, orientations, mecanum angles from the robot USD. Apply via WheeledRobot.apply_wheel_actions.

2D MobilityGen action [lin, ang] → 3D holonomic command [forward, lateral=0, yaw]. See mobility-gen for the WheeledMobilityGenRobot.build() override pattern.

DifferentialController + Articulation (Kit 110)

from isaacsim.robot.experimental.wheeled_robots.controllers import DifferentialController
from isaacsim.core.experimental.prims import Articulation
import numpy as np

robot = Articulation("/World/Robot")
robot.initialize_cpp_data_view()

dc = DifferentialController(wheel_radius=0.15, wheel_base=1.52)
wheel_vels = dc.forward(np.array([linear_speed, angular_speed]))

vel_targets = np.zeros((1, num_dofs))
for i in left_wheel_indices:  vel_targets[0, i] = wheel_vels[0]
for i in right_wheel_indices: vel_targets[0, i] = wheel_vels[1]
robot.set_dof_velocity_targets(vel_targets)

World Transform Extraction

BBoxCache.ComputeWorldBound() returns LOCAL bounds for Cube prims — wrong for world position. For actual world position use:

xf_cache = UsdGeom.XformCache(Usd.TimeCode.Default())
world_mat = xf_cache.GetLocalToWorldTransform(prim)
position = world_mat.ExtractTranslation()

For simulated position (Articulation runtime, not authored), use:

pos_wp, quat_wp = robot.get_world_poses()
pos = pos_wp.numpy()[0]    # shape (3,)
quat = quat_wp.numpy()[0]  # shape (4,) [w,x,y,z]

XformCache reads authored USD. Articulation.get_world_poses() reads simulated state.

Look-At Chase Camera (MANDATORY pattern)

Never use manual rotation matrices for chase cameras. Always use look-at:

from pxr import Gf

def look_at(eye, target, up=Gf.Vec3d(0, 0, 1)):
    fwd = (target - eye).GetNormalized()
    right = Gf.Vec3d.GetCross(fwd, up).GetNormalized()
    cam_up = Gf.Vec3d.GetCross(right, fwd)
    # USD camera: -Z is forward
    return Gf.Matrix4d(
        right[0],  right[1],  right[2],  0,
        cam_up[0], cam_up[1], cam_up[2], 0,
        -fwd[0],  -fwd[1],   -fwd[2],   0,
        eye[0],    eye[1],    eye[2],   1)

Standard camera offsets:

• Chase: 4m behind robot, 2.5m up, looking at robot center
• Overhead: 10m up, looking straight down
• POV: at robot front (1.26m forward), 0.8m height

Degenerate Up-Vector

When camera looks straight down (fwd ≈ 0,0,−1), cross(fwd, up=(0,0,1)) is zero → broken matrix → blank render. Always fallback:

up = Gf.Vec3d(0, 0, 1)
if abs(fwd * up) > 0.99:
    up = Gf.Vec3d(0, 1, 0)

Common Gotchas (shared across all navigation skills)

1. Feet/wheels below origin: many robots (Spot ~0.69 m, H1 ~1.05 m) have their articulation origin above the ground contact. Always call compute_robot_footprint(stage, root) and spawn at z = ground + fp["z_offset"].
2. Instancing invisible in headless Hydra: instanceable=true prims don't render in arm64 headless. Flatten first.
3. OmniGraph crashes on out-of-range frames: jumping past endTimeCode crashes PushGraph camera animation nodes.
4. next_update_async: doesn't exist in Isaac Sim 6 — use omni.kit.app.get_app().next_update_async().
5. Per-frame yaw smoothing: current_yaw += yaw_diff * 0.15 for smooth turning instead of instant snapping.
6. Frame numbering for ffmpeg: sequential frame_0000.png, frame_0001.png... NOT sparse — ffmpeg skips gaps.
7. Routes need lit zones: A* paths through dark corridors render as black frames. Define route waypoints in populated/lit areas, or add SphereLights at Z=3m along the route (intensity 800, radius 0.3).

Integration Points

• RECEIVES from: occupancy-map — map.yaml + map.png pair
• RECEIVES from: any USD scene with traversable geometry
• PRODUCES for: isaac-sim-robot-navigation — primitives for runtime navigation
• PRODUCES for: mobility-gen — primitives for SDG record/replay

Specialization Skills (read after this one)