CBF-RL: Safety Filtering Reinforcement Learning in Training with Control Barrier Functions

Safe reinforcement learning (RL) for robotic systems requires policies that improve task performance while satisfying state and input constraints during both training and deployment. Control barrier functions (CBFs) provide a principled mechanism for enforcing forward invariance through minimally invasive safety filters, but their use in model-free RL is limited by the need for accurate dynamics and hand-designed barrier certificates. We propose Robust Koopman-CBF SAC, a safety-filtered actor--critic framework that learns a finite-dimensional Koopman predictor from data, constructs affine CBF constraints in the lifted space, and enforces them through a quadratic-program safety layer. To account for finite-dimensional Koopman approximation error, the CBF condition is tightened using a projected residual margin estimated from held-out rollout data. The critic is trained on the executed safe action, while the actor is regularized toward the Koopman-CBF feasible set, reducing dependence on the filter over training. Across safe-control benchmarks, the method achieves zero constraint violations on CartPole stabilization and tracking while matching or exceeding unconstrained SAC returns. On high-dimensional Safety Gymnasium locomotion tasks, the method reduces violations in some settings but also exposes important limitations of first-order velocity barriers and linear EDMD models, motivating high-order and multi-step Koopman-CBF extensions. These results suggest that robust Koopman-CBF filters are a promising bridge between model-free RL and certifiable safety, while clarifying the structural conditions under which such filters remain effective.

Reinforcement Learning (RL) has demonstrated remarkable capabilities for solving complex robotic control problems, but its lack of safety guarantees severely limits deployment on hardware. In particular, as legged robots and manipulators often operate near safety-critical boundaries, out-of-distribution states can lead to failure upon deployment. To address this, we introduce Acc-CBF-QP, an acceleration-based Quadratic Program (QP) safety filter using Control Barrier Functions (CBFs) that constrains any RL policy onto a safe set at runtime without modifying training. The method applies to unconstrained and Safe-RL policies, and enforces joint position, velocity, torque, and collision constraints within a unified optimization framework. A key contribution is the formulation of RL+QP tasks that regulate deviation from the RL command when constraints would otherwise be violated. We introduce a TorqueTask, minimizing torque deviation, and a Forward Dynamics Task, minimizing induced acceleration deviation, thus providing principled control over safety-performance trade-offs. Experiments on a 7-DoF Kinova Gen3 manipulator and a 19-DoF Unitree H1 humanoid, both in simulation and on hardware, highlight substantial reductions in constraint violations. On the real H1 hardware, a Safe-RL policy alone yielded 10.04 violations/s, which were reduced by 92% to 0.80 violations/s when augmented with Acc-CBF-QP. On the Kinova Gen3, Acc-CBF-QP fully eliminated violations. Nominal task performance of the RL objective is preserved in violation-free regimes. Under aggressive velocity commands on H1, Acc-CBF-QP improves execution by preventing constraint-induced shutdowns, yielding longer survival times. The full pipeline is open-source.

Robot learning has produced remarkably effective ``black-box'' controllers for complex tasks such as dynamic locomotion on humanoids. Yet ensuring dynamic safety, i.e., constraint satisfaction, remains challenging for such policies. Reinforcement learning (RL) embeds constraints heuristically through reward engineering, and adding or modifying constraints requires retraining. Model-based approaches, like control barrier functions (CBFs), enable runtime constraint specification with formal guarantees but require accurate dynamics models. This paper presents SHIELD, a layered safety framework that bridges this gap by: (1) training a generative, stochastic dynamics residual model using real-world data from hardware rollouts of the nominal controller, capturing system behavior and uncertainties; and (2) adding a safety layer on top of the nominal (learned locomotion) controller that leverages this model via a stochastic discrete-time CBF formulation enforcing safety constraints in probability. The result is a minimally-invasive safety layer that can be added to the existing autonomy stack to give probabilistic guarantees of safety that balance risk and performance. In hardware experiments on an Unitree G1 humanoid, SHIELD enables safe navigation (obstacle avoidance) through varied indoor and outdoor environments using a nominal (unknown) RL controller and onboard perception.