Adaptive Safety Filtering for Frozen ACC Policies via Conformal Residual Calibration

Safety filters have been shown to be effective tools to ensure the safety of control systems with unsafe nominal policies. To address scalability challenges in traditional synthesis methods, learning-based approaches have been proposed for designing safety filters for systems with high-dimensional state and control spaces. However, the inevitable errors in the decisions of these models raise concerns about their reliability and the safety guarantees they offer. This paper presents Adaptive Conformal Filtering (ACoFi), a method that combines learned Hamilton-Jacobi reachability-based safety filters with adaptive conformal inference. Under ACoFi, the filter dynamically adjusts its switching criteria based on the observed errors in its predictions of the safety of actions. The range of possible safety values of the nominal policy's output is used to quantify uncertainty in safety assessment. The filter switches from the nominal policy to the learned safe one when that range suggests it might be unsafe. We show that ACoFi guarantees that the rate of incorrectly quantifying uncertainty in the predicted safety of the nominal policy is asymptotically upper bounded by a user-defined parameter. This gives a soft safety guarantee rather than a hard safety guarantee. We evaluate ACoFi in a Dubins car simulation and a Safety Gymnasium environment, empirically demonstrating that it significantly outperforms the baseline method that uses a fixed switching threshold by achieving higher learned safety values and fewer safety violations, especially in out-of-distribution scenarios.

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.

Safety in reinforcement learning is often specified through cumulative cost constraints, but these trajectory-level guarantees do not directly prevent unsafe individual decisions, especially under nonstationarity. In continual and nonstationary settings, the difficulty is amplified because the risk associated with the same action can vary across contexts, while a fixed state-level threshold may be either too conservative or too weak. We propose Constraint Projection Safety Shield (CPSS), a runtime mechanism that converts a cumulative safety budget into adaptive state-level control constraints during execution. CPSS tracks the remaining safety budget, projects it into a time-varying admissible risk threshold, and filters policy actions whose predicted safety cost exceeds the active threshold. The threshold is adjusted online using contextual signals so that enforcement becomes stricter in more demanding or rapidly changing regimes and less restrictive when the available safety budget is sufficient. We analyze the resulting shielded policy and show that the mechanism guarantees per-state threshold satisfaction for executed actions, induces finite-horizon cumulative cost bounds, and yields a performance degradation bound in terms of intervention frequency and per-step reward distortion. We evaluate CPSS in nonstationary highway merging scenarios using highway-env. Across multiple seeds, CPSS substantially reduces proximity-based safety violations and increases separation margins while intervening selectively rather than dominating the learned policy. These results support adaptive budget-to-threshold projection as a practical way to transform cumulative safety specifications into effective local safety control for continual reinforcement learning systems.