test(evo1): cover reconcile re-padding of overridden normalizer stats

Regression test for the stage2-from-checkpoint crash: reloading a
checkpoint with raw (unpadded) dataset stats injected via processor
overrides must be re-padded to max_state_dim/max_action_dim by
reconcile_evo1_processors, otherwise normalizing the padded state
raises a shape mismatch.

Co-authored-by: Cursor <cursoragent@cursor.com>

src/lerobot/policies/evo1/processor_evo1.py

@@ -302,6 +302,33 @@ def _pad_evo1_stats(
     return padded_stats
 
 
+def _refresh_evo1_normalization_steps(
+    config: Evo1Config,
+    preprocessor: PolicyProcessorPipeline,
+    postprocessor: PolicyProcessorPipeline,
+) -> None:
+    """Re-pad checkpoint-loaded (un)normalizer stats/features to EVO1's fixed widths.
+
+    Loading a checkpoint injects the raw dataset stats (unpadded to max_state_dim/max_action_dim)
+    into the (un)normalizer via the generic override path in make_pre_post_processors. Those stats
+    and their declared features must be re-padded/reshaped to EVO1's fixed widths, otherwise
+    normalization fails against the padded state/action tensors (e.g. state padded to 24 vs. 8-dim
+    LIBERO stats). Padding is a no-op when stats are already at the target width.
+    """
+    normalization_features = _evo1_normalization_features(config)
+    action_features = _evo1_action_features(config)
+    for step in preprocessor.steps:
+        if isinstance(step, NormalizerProcessorStep):
+            step.features = normalization_features
+            step.stats = _pad_evo1_stats(config, step.stats)
+            step.to(device=step.device, dtype=step.dtype)
+    for step in postprocessor.steps:
+        if isinstance(step, UnnormalizerProcessorStep):
+            step.features = action_features
+            step.stats = _pad_evo1_stats(config, step.stats)
+            step.to(device=step.device, dtype=step.dtype)
+
+
 def reconcile_evo1_processors(
     config: Evo1Config,
     preprocessor: PolicyProcessorPipeline,
@@ -309,16 +336,19 @@ def reconcile_evo1_processors(
 ) -> tuple[PolicyProcessorPipeline, PolicyProcessorPipeline]:
     """Reconcile checkpoint-loaded pipelines with the current EVO1 config.
 
-    Two things cannot be restored from a serialized pipeline alone: the EVO1 batch converter
-    (converters are plain functions and are never serialized), and eval-time CLI overrides of the
-    action postprocessing flags (`postprocess_action_dim`, `binarize_gripper`, `gripper_*`). This
-    restores the converter and rebuilds the action step from the current config so those overrides
-    take effect.
+    Three things cannot be restored from a serialized pipeline alone: the EVO1 batch converter
+    (converters are plain functions and are never serialized), eval-time CLI overrides of the
+    action postprocessing flags (`postprocess_action_dim`, `binarize_gripper`, `gripper_*`), and the
+    (un)normalizer stats/features when the generic override path injects raw, unpadded dataset
+    stats. This restores the converter, re-pads the normalization stats to EVO1's fixed widths, and
+    rebuilds the action step from the current config so those overrides take effect.
     """
     # Pipelines reloaded from a checkpoint come back with the default batch converter, which drops
     # non-observation extras (embodiment_id, state_mask, custom task fields) needed by EVO1.
     preprocessor.to_transition = evo1_batch_to_transition
 
+    _refresh_evo1_normalization_steps(config, preprocessor, postprocessor)
+
     action_step = Evo1ActionProcessorStep(
         action_dim=_evo1_action_dim(config),
         binarize_gripper=config.binarize_gripper,

tests/policies/evo1/test_evo1.py

@@ -496,6 +496,60 @@ def test_evo1_processor_save_load_round_trip_applies_config_overrides(tmp_path):
     assert "embodiment_id" in processed
 
 
+def test_reconcile_evo1_processors_repads_overridden_stats(tmp_path):
+    """Loading a checkpoint and injecting raw (unpadded) dataset stats must be re-padded.
+
+    Regression test: lerobot-train passes the raw dataset stats as normalizer/unnormalizer
+    overrides when resuming from a checkpoint (e.g. stage2 from a stage1 checkpoint). Those stats
+    are at the dataset dims (e.g. LIBERO state=8/action=7), but EVO1 pads state/action to
+    max_state_dim/max_action_dim before normalization, so reconcile_evo1_processors must re-pad the
+    stats or normalization crashes with a shape mismatch.
+    """
+    config = make_config()
+    preprocessor, postprocessor = make_evo1_pre_post_processors(config, dataset_stats=make_stats())
+    preprocessor.save_pretrained(tmp_path)
+    postprocessor.save_pretrained(tmp_path)
+
+    # Reload with the generic override path injecting raw, unpadded dataset stats.
+    raw_stats = make_stats()
+    loaded_pre = PolicyProcessorPipeline.from_pretrained(
+        tmp_path,
+        config_filename=f"{POLICY_PREPROCESSOR_DEFAULT_NAME}.json",
+        overrides={"normalizer_processor": {"stats": raw_stats}},
+        to_transition=batch_to_transition,
+        to_output=transition_to_batch,
+    )
+    loaded_post = PolicyProcessorPipeline.from_pretrained(
+        tmp_path,
+        config_filename=f"{POLICY_POSTPROCESSOR_DEFAULT_NAME}.json",
+        overrides={"unnormalizer_processor": {"stats": raw_stats}},
+        to_transition=policy_action_to_transition,
+        to_output=transition_to_policy_action,
+    )
+
+    # Sanity: the override really injected unpadded stats before reconciliation.
+    normalizer = next(step for step in loaded_pre.steps if isinstance(step, NormalizerProcessorStep))
+    assert normalizer._tensor_stats[OBS_STATE]["min"].shape == (STATE_DIM,)
+
+    loaded_pre, loaded_post = reconcile_evo1_processors(config, loaded_pre, loaded_post)
+
+    normalizer = next(step for step in loaded_pre.steps if isinstance(step, NormalizerProcessorStep))
+    unnormalizer = next(step for step in loaded_post.steps if isinstance(step, UnnormalizerProcessorStep))
+    assert normalizer._tensor_stats[OBS_STATE]["min"].shape == (MAX_STATE_DIM,)
+    assert normalizer._tensor_stats[ACTION]["min"].shape == (MAX_ACTION_DIM,)
+    assert unnormalizer._tensor_stats[ACTION]["min"].shape == (MAX_ACTION_DIM,)
+
+    # Normalizing a padded state must not raise (this is the exact runtime path that crashed).
+    processed = loaded_pre(
+        {
+            "task": "pick the block",
+            OBS_STATE: torch.zeros(STATE_DIM),
+            f"{OBS_IMAGES}.front": torch.rand(3, 16, 16),
+        }
+    )
+    assert processed[OBS_STATE].shape == (1, MAX_STATE_DIM)
+
+
 def test_evo1_policy_forward_and_inference_use_batched_embedding(monkeypatch):
     monkeypatch.setattr(modeling_evo1, "Evo1Model", DummyEvo1Model)
     policy = modeling_evo1.Evo1Policy(make_config())