Runtime Safety Filtering for Two-Terminal Hazards in Robotic Battery Recycling
Authors: Yuxin Cao, Wei Song, Xianglin Yang, Fusen Guo, Lin Li, Xiao Cheng, Jin Song Dong
Abstract
Runtime safety filters for learned manipulation policies typically define unsafe states as unions of object-wise keep-out regions. This representation can be unnecessarily restrictive for hazards that depend on a joint spatial relation, such as battery recycling, where a conductive payload can short a charged cell only when it approaches both terminals simultaneously. We study runtime filtering for this two-terminal hazard in LIBERO using frozen OpenVLA policies. We factor a runtime filter into three design choices: the predicate structure, its geometric margin, and the fallback action applied when a commanded action is rejected. We compare a conjunctive predicate, a conventional two-site keep-out, and a composite of the two. For each predicate, we vary its margin to obtain a frontier between task success and residual hazard. We then compare four fallback strategies at matched operating points: holding, retreat, sampled search, and a continuous-action barrier projection. Across three workcells, the three predicate families trace nearly identical safety--utility frontiers once each is evaluated over its own margin. In contrast, the fallback strategy has a substantially larger effect: holding reduces task success by up to 0.302 relative to retreat without reducing hazard, while both minimally invasive fallbacks leave substantially more residual hazard. This ordering transfers to a second policy and task suite, while retreat-based filtering remains effective under standing errors in the clearances available to the filter, although correlated error in the estimated payload size is more damaging than larger independent errors in terminal position. These results show that, for proximity-defined manipulation hazards, margin selection and fallback strategy can matter more than predicate structure in determining the safety--utility trade-off of a runtime filter.
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.
Safety-critical autonomy in unstructured environments poses significant challenges for online safety certification under evolving constraints. We propose Policy Library Control Barrier Function~(PL-CBF), a runtime safety filter that evaluates a library of fallback policies via parallel finite-horizon rollouts, selects the least invasive safe mode, and enforces safety by solving a quadratic program that minimally modifies a nominal policy. We provide a theoretical analysis based on a finite-horizon language metric over closed-loop behaviors, characterizing policy-library coverage requirements for certifying finite-horizon safety. Simulations on a planar double-integrator (4 states), highway driving with abrupt friction changes using a realistic nonlinear vehicle model (8 states), and 3D quadrotor navigation in crowded dynamic environments (12 states) demonstrate improved safety coverage over single-policy safety filters while retaining millisecond-level runtime.
Reinforcement learning (RL) policies enable dynamic legged locomotion but lack mechanisms to avoid violations of safety constraints that are absent during training. Large-scale offline safe learning is impractical for covering all edge cases. Existing safety frameworks either rely on reduced-order models that cannot reason about whole-body behaviors or require conservative recovery controllers that degrade task performance. We propose a predictive safety filter that post-hoc filters the nominal contact locations fed to the RL policy. When a collision is predicted, a sampling-based optimizer asynchronously searches for safer contact sequences using a full-physics model, while a learned value function bootstraps long-horizon returns. Our three algorithmic components (geometric projection of sampled contacts, momentum-augmented updates, and replica-exchange) make the optimization tractable in a discontinuous contact landscape. We validate the filter on a quadruped robot in dense, cluttered environments, both in simulation and in the real world, showing substantial reductions in safety violations with minimal deviation from the nominal input.
Aditya Shirwatkar, Sebastian Sanokowski, Shishir Kolathaya +2