Denoising Tells When to Replan: Denoising-Variance Adaptive Chunking for Flow-Based Robot Policies

Action chunking has become a common inference strategy for flow-based robot policies, improving action coherence by modeling multi-step temporal dependencies in demonstrations. However, the execution horizon is still typically set as an empirical fixed value, overlooking that predictable free-space motions and precision-critical interaction phases often require different replanning frequencies. In this work, we first show that the denoising process of flow-based policies contains an intrinsic signal of task phases: clean-action estimates remain stable during predictable motion phases, but fluctuate more strongly around contact-rich or precision-sensitive operations. Motivated by this observation, we propose DVAC (Denoising-Variance Adaptive Chunking), a test-time method that adaptively determines how many actions to execute from each predicted chunk. DVAC measures the variance of clean-action estimates over the final denoising steps, executes the stable low-variance prefix, and replans before high-variance future actions are committed. To transfer across tasks and rollouts, DVAC further calibrates the threshold with a rolling estimate of the local variance scale. Experiments on LIBERO, RoboTwin, CALVIN, and real-world manipulation show that DVAC improves task success while reducing replanning frequency. With a π0.5-based policy, DVAC improves LIBERO success from 94.75% to 98.00% and reduces replanning by 43.0%, while also yielding aggregate gains on RoboTwin and CALVIN and improving real-world execution efficiency.