Enhancing Robot Safety via MLLM-Based Semantic Interpretation of Failure Data

As robotic systems become increasingly integrated into real-world environments, ranging from autonomous vehicles to household assistants, they inevitably encounter diverse and unstructured scenarios that lead to failures. While such failures pose safety and reliability challenges, they also provide rich perceptual data for improving future performance. However, manually analyzing large-scale failure datasets is impractical. In this work, we present a method for automatically organizing large-scale robotic failure data into semantically meaningful clusters, enabling scalable learning from failure without human supervision. Our approach leverages the reasoning capabilities of Multimodal Large Language Models (MLLMs), trained on internet-scale data, to infer high-level failure causes from raw perceptual trajectories and discover interpretable structure within uncurated failure logs. These semantic clusters reveal latent patterns and hypothesized causes of failure, enabling scalable learning from experience. We demonstrate that the discovered failure modes can guide targeted data collection for policy refinement, accelerating iterative improvement in agent policies and overall safety. Additionally, we show that these semantic clusters can be employed for online failure detection, offering a lightweight yet powerful safeguard for real-time adaptation. We demonstrate that this framework enhances robot learning and robustness by transforming real-world failures into actionable and interpretable signals for adaptation.

Reachability Barrier Networks: Learning Hamilton-Jacobi Solutions for Smooth and Flexible Control Barrier Functions

Recent developments in autonomous driving and robotics underscore the necessity of safety-critical controllers. Control barrier functions (CBFs) are a popular method for appending safety guarantees to a general control framework, but they are notoriously difficult to generate beyond low dimensions. Existing methods often yield non-differentiable or inaccurate approximations that lack integrity, and thus fail to ensure safety. In this work, we use physics-informed neural networks (PINNs) to generate smooth approximations of CBFs by computing Hamilton-Jacobi (HJ) optimal control solutions. These reachability barrier networks (RBNs) avoid traditional dimensionality constraints and support the tuning of their conservativeness post-training through a parameterized discount term. To ensure robustness of the discounted solutions, we leverage conformal prediction methods to derive probabilistic safety guarantees for RBNs. We demonstrate that RBNs are highly accurate in low dimensions, and safer than the standard neural CBF approach in high dimensions. Namely, we showcase the RBNs in a 9D multi-vehicle collision avoidance problem where it empirically proves to be 5.5x safer and 1.9x less conservative than the neural CBFs, offering a promising method to synthesize CBFs for general nonlinear autonomous systems.

Bridging Model Predictive Control and Deep Learning for Scalable Reachability Analysis

Hamilton-Jacobi (HJ) reachability analysis is a widely used method for ensuring the safety of robotic systems. Traditional approaches compute reachable sets by numerically solving an HJ Partial Differential Equation (PDE) over a grid, which is computationally prohibitive due to the curse of dimensionality. Recent learning-based methods have sought to address this challenge by approximating reachability solutions using neural networks trained with PDE residual error. However, these approaches often suffer from unstable training dynamics and suboptimal solutions due to the weak learning signal provided by the residual loss. In this work, we propose a novel approach that leverages model predictive control (MPC) techniques to guide and accelerate the reachability learning process. Observing that HJ reachability is inherently rooted in optimal control, we utilize MPC to generate approximate reachability solutions at key collocation points, which are then used to tactically guide the neural network training by ensuring compliance with these approximations. Moreover, we iteratively refine the MPC generated solutions using the learned reachability solution, mitigating convergence to local optima. Case studies on a 2D vertical drone, a 13D quadrotor, a 7D F1Tenth car, and a 40D publisher-subscriber system demonstrate that bridging MPC with deep learning yields significant improvements in the robustness and accuracy of reachable sets, as well as corresponding safety assurances, compared to existing methods.

DualGuard MPPI: Safe and Performant Optimal Control by Combining Sampling-Based MPC and Hamilton-Jacobi Reachability

Designing controllers that are both safe and performant is inherently challenging. This co-optimization can be formulated as a constrained optimal control problem, where the cost function represents the performance criterion and safety is specified as a constraint. While sampling-based methods, such as Model Predictive Path Integral (MPPI) control, have shown great promise in tackling complex optimal control problems, they often struggle to enforce safety constraints. To address this limitation, we propose DualGuard-MPPI, a novel framework for solving safety-constrained optimal control problems. Our approach integrates Hamilton-Jacobi reachability analysis within the MPPI sampling process to ensure that all generated samples are provably safe for the system. On the one hand, this integration allows DualGuard-MPPI to enforce strict safety constraints; at the same time, it facilitates a more effective exploration of the environment with the same number of samples, reducing the effective sampling variance and leading to better performance optimization. Through several simulations and hardware experiments, we demonstrate that the proposed approach achieves much higher performance compared to existing MPPI methods, without compromising safety.

One Filter to Deploy Them All: Robust Safety for Quadrupedal Navigation in Unknown Environments

As learning-based methods for legged robots rapidly grow in popularity, it is important that we can provide safety assurances efficiently across different controllers and environments. Existing works either rely on a priori knowledge of the environment and safety constraints to ensure system safety or provide assurances for a specific locomotion policy. To address these limitations, we propose an observation-conditioned reachability-based (OCR) safety-filter framework. Our key idea is to use an OCR value network (OCR-VN) that predicts the optimal control-theoretic safety value function for new failure regions and dynamic uncertainty during deployment time. Specifically, the OCR-VN facilitates rapid safety adaptation through two key components: a LiDAR-based input that allows the dynamic construction of safe regions in light of new obstacles and a disturbance estimation module that accounts for dynamics uncertainty in the wild. The predicted safety value function is used to construct an adaptive safety filter that overrides the nominal quadruped controller when necessary to maintain safety. Through simulation studies and hardware experiments on a Unitree Go1 quadruped, we demonstrate that the proposed framework can automatically safeguard a wide range of hierarchical quadruped controllers, adapts to novel environments, and is robust to unmodeled dynamics without a priori access to the controllers or environments - hence, "One Filter to Deploy Them All". The experiment videos can be found on the project website.

Enhancing Safety and Robustness of Vision-Based Controllers via Reachability Analysis

Autonomous systems, such as self-driving cars and drones, have made significant strides in recent years by leveraging visual inputs and machine learning for decision-making and control. Despite their impressive performance, these vision-based controllers can make erroneous predictions when faced with novel or out-of-distribution inputs. Such errors can cascade into catastrophic system failures and compromise system safety. In this work, we compute Neural Reachable Tubes, which act as parameterized approximations of Backward Reachable Tubes to stress-test the vision-based controllers and mine their failure modes. The identified failures are then used to enhance the system safety through both offline and online methods. The online approach involves training a classifier as a run-time failure monitor to detect closed-loop, system-level failures, subsequently triggering a fallback controller that robustly handles these detected failures to preserve system safety. For the offline approach, we improve the original controller via incremental training using a carefully augmented failure dataset, resulting in a more robust controller that is resistant to the known failure modes. In either approach, the system is safeguarded against shortcomings that transcend the vision-based controller and pertain to the closed-loop safety of the overall system. We validate the proposed approaches on an autonomous aircraft taxiing task that involves using a vision-based controller to guide the aircraft towards the centerline of the runway. Our results show the efficacy of the proposed algorithms in identifying and handling system-level failures, outperforming methods that rely on controller prediction error or uncertainty quantification for identifying system failures.

System-Level Safety Monitoring and Recovery for Perception Failures in Autonomous Vehicles

The safety-critical nature of autonomous vehicle (AV) operation necessitates development of task-relevant algorithms that can reason about safety at the system level and not just at the component level. To reason about the impact of a perception failure on the entire system performance, such task-relevant algorithms must contend with various challenges: complexity of AV stacks, high uncertainty in the operating environments, and the need for real-time performance. To overcome these challenges, in this work, we introduce a Q-network called SPARQ (abbreviation for Safety evaluation for Perception And Recovery Q-network) that evaluates the safety of a plan generated by a planning algorithm, accounting for perception failures that the planning process may have overlooked. This Q-network can be queried during system runtime to assess whether a proposed plan is safe for execution or poses potential safety risks. If a violation is detected, the network can then recommend a corrective plan while accounting for the perceptual failure. We validate our algorithm using the NuPlan-Vegas dataset, demonstrating its ability to handle cases where a perception failure compromises a proposed plan while the corrective plan remains safe. We observe an overall accuracy and recall of 90% while sustaining a frequency of 42Hz on the unseen testing dataset. We compare our performance to a popular reachability-based baseline and analyze some interesting properties of our approach in improving the safety properties of an AV pipeline.

Updating Robot Safety Representations Online from Natural Language Feedback

Robots must operate safely when deployed in novel and human-centered environments, like homes. Current safe control approaches typically assume that the safety constraints are known a priori, and thus, the robot can pre-compute a corresponding safety controller. While this may make sense for some safety constraints (e.g., avoiding collision with walls by analyzing a floor plan), other constraints are more complex (e.g., spills), inherently personal, context-dependent, and can only be identified at deployment time when the robot is interacting in a specific environment and with a specific person (e.g., fragile objects, expensive rugs). Here, language provides a flexible mechanism to communicate these evolving safety constraints to the robot. In this work, we use vision language models (VLMs) to interpret language feedback and the robot's image observations to continuously update the robot's representation of safety constraints. With these inferred constraints, we update a Hamilton-Jacobi reachability safety controller online via efficient warm-starting techniques. Through simulation and hardware experiments, we demonstrate the robot's ability to infer and respect language-based safety constraints with the proposed approach.

Cooptimizing Safety and Performance with a Control-Constrained Formulation

Autonomous systems have witnessed a rapid increase in their capabilities, but it remains a challenge for them to perform tasks both effectively and safely. The fact that performance and safety can sometimes be competing objectives renders the cooptimization between them difficult. One school of thought is to treat this cooptimization as a constrained optimal control problem with a performance-oriented objective function and safety as a constraint. However, solving this constrained optimal control problem for general nonlinear systems remains challenging. In this work, we use the general framework of constrained optimal control, but given the safety state constraint, we convert it into an equivalent control constraint, resulting in a state and time-dependent control-constrained optimal control problem. This equivalent optimal control problem can readily be solved using the dynamic programming principle. We show the corresponding value function is a viscosity solution of a certain Hamilton-Jacobi-Bellman Partial Differential Equation (HJB-PDE). Furthermore, we demonstrate the effectiveness of our method with a two-dimensional case study, and the experiment shows that the controller synthesized using our method consistently outperforms the baselines, both in safety and performance.

Stable-BC: Controlling Covariate Shift with Stable Behavior Cloning

Behavior cloning is a common imitation learning paradigm. Under behavior cloning the robot collects expert demonstrations, and then trains a policy to match the actions taken by the expert. This works well when the robot learner visits states where the expert has already demonstrated the correct action; but inevitably the robot will also encounter new states outside of its training dataset. If the robot learner takes the wrong action at these new states it could move farther from the training data, which in turn leads to increasingly incorrect actions and compounding errors. Existing works try to address this fundamental challenge by augmenting or enhancing the training data. By contrast, in our paper we develop the control theoretic properties of behavior cloned policies. Specifically, we consider the error dynamics between the system's current state and the states in the expert dataset. From the error dynamics we derive model-based and model-free conditions for stability: under these conditions the robot shapes its policy so that its current behavior converges towards example behaviors in the expert dataset. In practice, this results in Stable-BC, an easy to implement extension of standard behavior cloning that is provably robust to covariate shift. We demonstrate the effectiveness of our algorithm in simulations with interactive, nonlinear, and visual environments. We also conduct experiments where a robot arm uses Stable-BC to play air hockey. See our website here: https://collab.me.vt.edu/Stable-BC/