Safe Execution of RL Policies Via Acceleration-Based CBF-QP Constraint Enforcement for Real-World Robotic Deployments
Authors: Bastien Muraccioli, Alice Cariou, Pierre-Alexandre Leziart, Mathieu Celerier, Arnaud Demont, Gentiane Venture, Mehdi Benallegue
Abstract
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), 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.
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 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.