Runtime Safety Filtering for Two-Terminal Hazards in Robotic Battery Recycling

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. 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.