CALOS: Control-Affine Lyapunov On-manifold Safety Layer for Safe Deep Reinforcement Learning for Quadrotors

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.

Deep Reinforcement Learning (DRL) for quadrotor flight control typically relies on Domain Randomization (DR) for sim-to-real transfer, resulting in overly conservative policies that struggle with dynamic disturbances. To overcome this, we propose a novel adaptive control architecture that actively perceives and reacts to instantaneous perturbations. First, we train an optimal outer-loop policy, then replace its reliance on ground-truth disturbance data with a Residual Dynamics Predictor (RDP). The RDP estimates the external forces and moments acting on the aircraft in flight online using only the history of states and control actions. For seamless hardware transfer, we introduce a data-efficient linear calibration bridge and an online thrust correction mechanism that align the simulated latent space with reality using mere seconds of flight data. Real-world validations on a Crazyflie micro-quadrotor demonstrate that our adaptive controller significantly outperforms baselines, maintaining precise trajectory tracking under severe uncertainties including mass variations, asymmetric payloads, and dynamic slung loads

Safe quadrotor navigation in cluttered and dynamic environments depends not only on instantaneous geometric perception, but more critically on anticipating collision risks induced by relative motion. Conventional modular pipelines frequently suffer from perception latency, while end-to-end learning methods relying on implicit scalar rewards often struggle to extract reliable spatio-temporal features without physics-grounded supervision. To address this, we propose an anticipatory risk-guided reinforcement learning framework. Leveraging privileged simulator states, we construct a directionally aligned future collision risk map based on the Closest Point of Approach (CPA). Through an asymmetric actor-critic architecture, the network is trained to self-predict this structured risk, which explicitly guides the visual policy during deployment. A lightweight spatio-temporal encoder extracts motion cues directly from onboard depth sequences, bypassing explicit object tracking or optical flow estimation. Extensive simulated and real-world experiments demonstrate that our method effectively improves safety margins and flight efficiency in dense dynamic clutters compared to existing baselines. Furthermore, the learned policy achieves robust zero-shot Sim-to-Real transfer on a physical quadrotor, relying purely on abstracted spatio-temporal depth sequences and its self-predicted risk priors, validating the effectiveness of our approach and its robust generalization from simulation to reality.