Warehouse Occupancy Map Generation

Generate ROS-compatible occupancy maps from USD warehouse scenes for navigation and perception training. Two paths: the documented isaacsim.asset.gen.omap extension (PhysX-collider-based, GUI + Python), and a direct USD-projection fallback for prototypes or non-collider scenes.

When to use

• Nav2 / MobilityGen / A* path planning setup.
• Perception training data generation.
• AMR fleet path planning validation.
• Collision-avoidance buffer-zone calculation.

Path 1 (recommended): isaacsim.asset.gen.omap extension

Documented in docs/isaacsim/digital_twin/ext_isaacsim_asset_generator_occupancy_map.rst (Mapping). The extension uses physics collision geometry, so every prim you want captured must have Collisions Enabled; the Start location cannot be occupied.

GUI workflow

1. Open the stage.
2. Tools > Robotics > Occupancy Map.
3. Set Origin (free point inside the area), Lower/Upper Bound (clamp the mapped extent), Cell Size, optionally toggle Use PhysX Collision Geometry.
4. CALCULATE, then VISUALIZE IMAGE to preview.
5. From the visualization window: Save Image (PNG) and Save YAML (ROS occupancy-map parameters file).

Python (programmatic, simulation playing)

from isaacsim.asset.gen.omap.bindings import _omap
import omni.physx
import omni.usd

physx   = omni.physx.acquire_physx_interface()
stage_id = omni.usd.get_context().get_stage_id()

generator = _omap.Generator(physx, stage_id)
generator.update_settings(
    cell_size=0.1,         # meters per pixel
    z_min=0.1,             # height to map at (m above origin)
    z_max=0.0,             # 0 = use cell_size
    occupancy_threshold=0.5,
)
generator.set_transform(origin=(0, 0, 0), lo_offset=(-10, -10, 0), hi_offset=(10, 10, 0))
generator.generate2d()
buffer = generator.get_buffer()    # raw occupancy data

Requires the timeline to be playing for PhysX raycasts. For headless runs, pair with app_utils.play(commit=True).

Path 2 (fallback): direct USD projection

Use when the scene lacks colliders, you need a deterministic projection from authored geometry, or you are prototyping with placeholder cubes. Faster and reproducible for those cases but does not respect physics collision approximations.

1. Extract Obstacles from USD

Read all prims, project XY footprint onto 2D grid. Filter by height to separate navigable floor markings from solid obstacles.

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

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

RESOLUTION = 0.1  # meters per pixel
ROBOT_HEIGHT_MIN = 0.05  # ignore floor markings below this
ROBOT_HEIGHT_MAX = 2.0   # robot clearance height

grid_w = int(facility_width / RESOLUTION)
grid_h = int(facility_depth / RESOLUTION)
grid = np.ones((grid_h, grid_w), dtype=np.uint8)  # 1=free

# Skip navigable prims (routes, floor, humans, exits, List below as a reference)
SKIP_PREFIXES = ("Floor", "FL", "AR", "HR", "FR", "AMR", "Exit", "Hum", "Divider", "Stair")

for prim in stage.TraverseAll():
    if not prim.IsA(UsdGeom.Gprim):
        continue
    name = prim.GetName()
    if any(name.startswith(p) for p in SKIP_PREFIXES):
        continue

    bbox = bbox_cache.ComputeWorldBound(prim)
    rng = bbox.ComputeAlignedRange()
    lo, hi = rng.GetMin(), rng.GetMax()

    if hi[2] * mpu < ROBOT_HEIGHT_MIN or lo[2] * mpu > ROBOT_HEIGHT_MAX:
        continue

    x_min = max(0, int(lo[0] * mpu / RESOLUTION))
    x_max = min(grid_w, int(hi[0] * mpu / RESOLUTION) + 1)
    y_min = max(0, int(lo[1] * mpu / RESOLUTION))
    y_max = min(grid_h, int(hi[1] * mpu / RESOLUTION) + 1)

    r_min = grid_h - y_max  # flip Y for image coords
    r_max = grid_h - y_min
    grid[r_min:r_max, x_min:x_max] = 2  # occupied

2. Apply Robot Buffer

from scipy.ndimage import binary_dilation

ROBOT_RADIUS = 0.5  # meters
buffer_px = int(ROBOT_RADIUS / RESOLUTION)
kernel_size = 2 * buffer_px + 1
kernel = np.zeros((kernel_size, kernel_size), dtype=bool)
for r in range(kernel_size):
    for c in range(kernel_size):
        if (r - buffer_px)**2 + (c - buffer_px)**2 <= buffer_px**2:
            kernel[r, c] = True
buffered = binary_dilation((grid == 2), structure=kernel)

3. Export ROS Format

from PIL import Image
import yaml

# Grayscale map (ROS standard)
img_data = np.full_like(grid, 205)  # grey=unknown
img_data[grid == 1] = 254  # white=free
img_data[grid == 2] = 0    # black=occupied
Image.fromarray(img_data, 'L').save("map.png")

# YAML config
yaml_data = {
    "image": "map.png",
    "resolution": RESOLUTION,
    "origin": [0.0, 0.0, 0.0],  # [x, y, yaw] of bottom-left pixel
    "negate": 0,
    "occupied_thresh": 0.65,
    "free_thresh": 0.196,
}
with open("map.yaml", "w") as f:
    yaml.dump(yaml_data, f, default_flow_style=False)

4. Generate Colored Visualization

color = np.zeros((grid_h, grid_w, 3), dtype=np.uint8)
color[grid == 1] = [255, 255, 255]  # white=free
color[grid == 2] = [0, 0, 0]        # black=occupied
color[buffered & (grid != 2)] = [255, 200, 200]  # pink=buffer
Image.fromarray(color, 'RGB').save("map_colored.png")

Key Design Decisions

What to Mark as Obstacles

• INCLUDE: Racks, GSRC modules, docks, tables, pack stations, conveyors (they're elevated but have supports), VLMs, sort equipment, walls, columns
• EXCLUDE: Floor plane, fire lane markings, AMR route overlays, human walkway markings, forklift lane markings, humans (they move), AMR robots (they move), exit signs, stairs (navigable)

Height Filtering

• z_max < 0.05m → floor marking, skip (route overlays are at z=0.02-0.04)
• z_min > 2.0m → above robot, skip (overhead conveyors at z=6+, HVAC at z=13+)
• Everything else in the 0.05-2.0m band → obstacle

Resolution Selection

Robot Buffer Sizing

Isaac Sim OccupancyMap Class

For integration with MobilityGen path planning:

from isaacsim.replicator.mobility_gen.impl.occupancy_map import OccupancyMap
omap = OccupancyMap.from_ros_yaml("map.yaml")
omap_buffered = omap.buffered_meters(0.5)
# Use with A* planner, spawn placement, etc.

Coordinate Conventions

• USD world: X=east, Y=north, Z=up (meters)
• Image: row 0 = top = max Y (north), col 0 = left = min X (west)
• ROS origin: [x, y, yaw] of bottom-left pixel in world coords
• world_to_pixel: world_x / resolution = col, (max_y - world_y) / resolution = row