We present a safe, real-time algorithm for active fault diagnosis and model discrimination for uncertain continuous-time nonlinear systems with process and measurement disturbances. Given a finite set of candidate models representing nominal and faulty modes, including actuator and sensor faults, we formulate an output-feedback, time-varying policy optimization problem that (i) robustly enforces state-input safety constraints over a finite horizon and (ii) drives the system to produce sampled measurements consistent with at most one model, enabling deterministic diagnosis. To solve this problem in real time, we develop a tractable approximation using interval over-approximations of reachable state and output sets, and encode diagnosability via a differentiable objective that penalizes overlap between the reachable output sets of possible models. The resulting optimization is solved efficiently online with gradient-based methods using JAX and differentiable reachability primitives. We evaluate our method on sensor and actuator fault diagnosis (up to 11 fault modes) in several high-dimensional nonlinear robotic systems, including a simulated quadrotor and fighter-jet model, a hardware differential-drive robot, and quadrupedal navigation. Across these case studies, our approach achieves reliable model discrimination in under 50 ms, outperforming baselines in discrimination success rate and speed while providing formal safety guarantees.
Neural network (NN) dynamics models and control policies achieve strong performance in robotics, but providing sound guarantees under uncertainty remains difficult, especially for closed-loop NN systems. Existing reachability tools provide formal over-approximations, yet are often non-differentiable, overly conservative, or too slow for modern learning and online planning pipelines. To address this, we present a parallelizable, differentiable reachability framework in JAX for continuous- and discrete-time systems with analytical and NN-based dynamics and controllers. Our framework combines Taylor-model flowpipe construction with CROWN-style linear bound propagation through a unified representation that preserves affine dependencies while supporting GPU-batched computation and automatic differentiation. Building on this reachability primitive, we develop (i) a certified training method that encourages reachability-friendly dynamics models and controllers, and (ii) a reachability-aware sampling-based MPC scheme with gradient-based refinement. Experiments on non-prehensile manipulation and quadrotor tasks, including hardware and higher-dimensional evaluations (up to 72D), demonstrate practical online planning while maintaining certified reachable-set over-approximations under bounded uncertainty.
Least-restrictive safety filters based on Hamilton-Jacobi reachability provide strong safety guarantees by overriding a nominal controller only when the system reaches the boundary of the set of unsafe states defined as a Backward Reachable Tube (BRT). These guarantees, however, rely on the continuous-time nature of the underlying formulation. In practice, robotic systems apply control at discrete sampling intervals, which creates a mismatch where the system may jump into the unsafe BRT between updates, allowing failures that are theoretically avoidable. This work introduces a principled solution based on a one-step expanded BRT that predicts all states capable of reaching the true BRT within a single timestep. By using this expanded boundary as the activation condition for the safety filter, safety interventions occur early enough to ensure correctness under discrete-time execution. We formulate this expanded set as a modified reachability problem and compute it using standard continuous-time solvers.
Differentiable predictive control (DPC), a self-supervised learning approach for approximating explicit model predictive control (MPC) policies, offers significant computational advantages over online optimization-based MPC. However, feasibility guarantees, a core requirement for safe control, are currently provided either probabilistically or via online safety filters. The lack of rigorous feasibility guarantees for offline policy optimization remains an open problem. This paper establishes deterministic feasibility guarantees for DPC using a novel topological analysis of the induced reachable safe set, without requiring online safety filters. By exploiting the inherent model-based nature of DPC, in which differentiable system dynamics are embedded directly into the computational graph, we analyze the properties of the learned control policies and the corresponding system states from topological and geometric perspectives. Inspired by our theoretical analysis, we propose a novel self-supervised offline policy learning strategy that utilizes a proxy loss with Control Barrier Functions (CBFs). Crucially, these properties not only significantly improve policy training but also enable the derivation of strict, deterministic feasibility guarantees from a finite number of training samples. Extensive closed-loop simulations validate our theoretical findings, demonstrating that the empirical constraint violations monotonically decrease to zero as the training sample size increases. Ultimately, this work illustrates that DPC policy optimization yields formal safety certificates that are structurally unattainable with conventional black-box methods, e.g., reinforcement learning (RL) or supervised learning-based approximate MPC, thereby providing a new perspective on feasibility guarantees in learning-based control.