Organizations: Carnegie Mellon University, Pittsburgh, PA, USA
Abstract
Safety critical control of robotic manipulation tasks involving deformable media such as fluids, cloth, and soft objects remains challenging because existing learning based approaches encode safety indirectly through reward shaping, which provides no guarantee of constraint satisfaction at deployment. We present a constraint driven online safety filter for deformable object manipulation that enforces explicit task level safety constraints in real time by minimally modifying any nominal control policy. Our approach combines two key components: a horizon agnostic neural operator that learns the boundary input output mapping of the underlying PDE dynamics and generalizes across variable rollout lengths without retraining, and a boundary control barrier function that certifies safety at the task relevant output level via a lightweight quadratic program. The resulting safety constraint is affine in the boundary input rate, enabling real time online filtering. We evaluate the proposed method on fluid manipulation tasks in FluidLab, where the filter improves safe trajectory rates by up to 22% over unfiltered base policies while also reducing the number of steps required to reach the safe set, demonstrating that constraint driven safety enforcement is both more reliable and more efficient than reward shaping approaches.
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.
Bastien Muraccioli, Alice Cariou, Pierre-Alexandre Leziart +4
Safe control of humanoid robots remains challenging due to their high-dimensional dynamics, contact-rich interactions, and sensitivity to disturbances. Although reinforcement learning has enabled effective locomotion and motion tracking, learned policies can still generate unsafe actions that lead to instability or falls. In this work, we propose residual reinforcement learning as an implicit safety-filtering mechanism for safe humanoid control. Instead of relying on a single nominal policy to simultaneously balance performance, safety, and robustness, we decouple performance and safety. The nominal policy focuses solely on task performance, while a residual policy learns safety corrections. This decoupling leads to a better performance--safety Pareto trade-off and avoids the need for careful tuning of multiple competing reward terms within a single policy training. We show that the residual policy can act as an implicit safety filter.
Reinforcement learning (RL), while powerful and expressive, can often prioritize performance at the expense of safety. Yet safety violations can lead to catastrophic outcomes in real-world deployments. Control Barrier Functions (CBFs) offer a principled method to enforce dynamic safety -- traditionally deployed online via safety filters. While the result is safe behavior, the fact that the RL policy does not have knowledge of the CBF can lead to conservative behaviors. This paper proposes CBF-RL, a framework for generating safe behaviors with RL by enforcing CBFs in training. CBF-RL has two key attributes: (1) minimally modifying a nominal RL policy to encode safety constraints via a CBF term, (2) and safety filtering of the policy rollouts in training. Theoretically, we prove that continuous-time safety filters can be deployed via closed-form expressions on discrete-time roll-outs. Practically, we demonstrate that CBF-RL internalizes the safety constraints in the learned policy -- both enforcing safer actions and biasing towards safer rewards -- enabling safe deployment without the need for an online safety filter. We validate our framework through ablation studies on navigation tasks and on the Unitree G1 humanoid robot, where CBF-RL enables safer exploration, faster convergence, and robust performance under uncertainty, enabling the humanoid robot to avoid obstacles and climb stairs safely in real-world settings without a runtime safety filter.