PPO-EAL: Exact Augmented Lagrangian Proximal Policy Optimization for Safe Robotic Control

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 achieved remarkable success in various robotic tasks; however, its deployment in real-world scenarios, particularly in contact-rich environments, often overlooks critical safety and stability aspects. Policies without passivity guarantees can result in system instability, posing risks to robots, their environments, and human operators. In this work, we investigate the limitations of traditional RL policies when deployed in contact-rich tasks and explore the combination of energy-based passive control with safe RL in both training and deployment to answer these challenges. Firstly, we reveal the discovery that standard RL policy does not satisfy stability in contact-rich scenarios. Secondly, we introduce a \textit{passivity-aware} RL policy training with energy-based constraints in our safe RL formulation. Lastly, a passivity filter is exerted on the policy output for \textit{passivity-ensured} control during deployment. We conduct comparative studies on a contact-rich robotic maze exploration task, evaluating the effects of learning passivity-aware policies and the importance of passivity-ensured control. The experiments demonstrate that a passivity-agnostic RL policy easily violates energy constraints in deployment, even though it achieves high task completion in training. The results show that our proposed approach guarantees control stability through passivity filtering and improves the energy efficiency through passivity-aware training. A video of real-world experiments is available as supplementary material. We also release the checkpoint model and offline data for pre-training at \href{https://huggingface.co/Anonymous998/passiveRL/tree/main}{Hugging Face}.

Safe reinforcement learning (Safe RL) aims to maximize expected return while satisfying safety constraints, typically modeled as Constrained Markov Decision Processes (CMDPs). While primal-dual methods scale well to deep RL, they often suffer from delayed constraint correction, leading to oscillatory behavior and prolonged safety violations. In this paper, we propose Constraint-Sensitive Policy Optimization (CSPO), a first-order primal-dual method that incorporates local constraint sensitivity into policy updates. CSPO augments the primal objective with a constraint-sensitive correction derived from the shortest signed distance to the safety boundary, enabling smarter recovery steps back to safety, compensating for delayed Lagrange multiplier updates, reducing oscillations near the boundary, and preserving the KKT solutions of the original constrained problem. Experiments on navigation and locomotion benchmarks demonstrate that CSPO achieves faster safety recovery and high reward preservation, resulting in higher constrained returns compared to state-of-the-art primal-dual and penalty-based methods