Residual Wrench Certification and Margin-Aware Control Synthesis for Aerial Physical Interaction

Fully actuated unmanned aerial vehicles (UAVs) are usually certified through rank conditions on a control-allocation matrix or through free-flight tracking performance. For aerial physical interaction, this certification may be incomplete. During sustained contact, part of the available wrench is consumed by the interaction task, and only the residual wrench remains available for stabilization, disturbance rejection, and maneuvering. This paper introduces a control-theoretic framework for \emph{contact-persistent full actuation}. A rigid-body model on $\R^{3}\times\SO\left(3\right)$ is combined with a morphology-dependent wrench map that captures fixed-tilt, variable-tilt, coaxial, and overactuated multirotor architectures. We define feasible wrench sets under actuator limits, residual wrench sets under task loading, and residual authority margins that strengthen the usual rank-based notion of full actuation. The main result shows that contact-persistent full actuation is equivalent to interiority of the task wrench in the constrained feasible wrench polytope, and that the residual authority radius is exactly the distance to the polytope boundary. We further introduce a signed residual-margin certificate for infeasible and boundary cases, a slack-maximizing allocation certificate, and a robust implementability condition that can be used as a margin-aware safety filter. Numerical evaluation on an abstract tilted hexarotor shows that full row rank alone does not imply feasible contact operation. Intermediate tilt angles preserve residual authority during pushing, whereas small or excessive tilts fail because of lateral-force deficiency or hover-margin loss.

We study high-order safety-critical control of quadrotor teams under bounded inputs and pairwise collision-avoidance constraints. Squared-distance barriers may lose thrust effectiveness when the relative displacement is orthogonal to the available thrust directions, while nonsingular constraints may still be jointly infeasible under shared bounds. We characterize both phenomena through pairwise effectiveness and aggregate feasibility measures. A torque-aware dynamic extension exposes attitude torques in a fourth-order barrier and prevents the extended-input row from vanishing under positive thrust. Gaussian processes directly learn the fourth-order HOCBF residual, providing robust margins without differentiating unknown perturbations. Under residual-bound and persistent-feasibility assumptions, the resulting QP guarantees collision avoidance and recovers the nominal input whenever it satisfies the robust safety and actuator constraints.

Control barrier functions for input-constrained systems place the admissible input set inside the definition of the safe set, yet the resulting barrier is almost always a function of the state alone; On a quadrotor this is not cosmetic: because the thrust vector must be reoriented before it can decelerate an approach, and reorientation is limited by the attainable body rate, a state-only barrier certifies states from which no escape is reachable in time; We characterize the certification gap in closed form and show its width is proportional to closing speed and inversely proportional to the body-rate limit; We then define an escape barrier on the augmented pair of state and previously applied input, with escape authority measured over the one-step reachable thrust cap; It admits a closed form and an analytic inverse for the maximum certifiable closing speed, and embeds in a predictive controller at no additional state cost; Across 550 paired closed-loop episodes on a 13-state quadrotor, the proposed controller completes every tested scenario, whereas the stopping-distance barrier enforced over the same horizon fails 15% and 25% of episodes in exactly the two scenarios that enter the predicted gap; Against an online backup-CBF baseline enforcing the same escape condition at the reached state, it holds a 29-74 degree larger directional margin and 3-18 times the clearance, and an independent conservative rollout referee finds no certified state from which escape fails.