COP-Q: Safety-First Reinforcement Learning for Robot Control via Cholesky-Ordered Projection

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.

Reinforcement learning (RL) has emerged as a promising solution to accomplish complex robotic control tasks; however, most of the current work ignores the safety requirements. Safe RL seeks to maximize task performance while satisfying explicit physical constraints, but current algorithms struggle to learn the policy efficiently with precise constraint satisfaction. This work proposes PPO-EAL, a novel first-order constrained policy optimization framework that integrates exact augmented Lagrangian optimization into proximal policy optimization for safe robotic control. By combining clipped policy updates with exact quadratic penalty terms, PPO-EAL achieves theoretically grounded constraint enforcement without requiring impractically large penalty factors. A momentum-regulated multiplier update further improves dual-variable stability, reducing constraint oscillation and unsafe behavior while preserving task performance. We provide exactness and convergence analysis under standard stochastic approximation assumptions. Extensive validation across diverse GPU-accelerated robotic benchmarks-including cart-pole balancing, cart-double-pendulum stabilization, 7-DoF Franka end-effector reaching, and quadrupedal locomotion-demonstrates superior safety precision and reward performance compared with state-of-the-art first-order safe RL baselines. Finally, we demonstrate zero-shot sim-to-real deployment in a contact-rich gear assembly task, where PPO-EAL substantially improves task success, reduces peak contact force, and enhances operational robustness. These results establish PPO-EAL as a general and practically deployable safe RL framework for diverse safety-critical robotic systems.

Ensuring safety during reinforcement learning (RL) training is critical in real-world applications where unsafe exploration can lead to devastating outcomes. While most safe RL methods mitigate risk through constraints or penalization, they still allow exploration of unsafe states during training. In this work, we adopt a stricter safety requirement that eliminates unsafe state visitation during training. To achieve this goal, we propose a Q-learning-based safe RL framework that leverages a behavior policy supported on a safe set. Under the assumption that the induced trajectories remain within the safe set, this policy enables sufficient exploration within the safe region without requiring near-optimality. We adopt a two-stage framework in which the Q-function and policy are trained separately. Specifically, we introduce a KL-regularized Bellman target that constrains the Q-function to remain close to the behavior policy. We then derive the policy induced from the trained Q-values and propose a parametric policy extraction method to approximate the optimal policy. Our approach provides a unified framework that can be adapted to different action spaces and types of behavior policies. Experimental results demonstrate that the proposed method achieves stable learning and well-calibrated value estimates and yields safer behavior with comparable or better performance than existing baselines.