Adaptive Safety Filtering for Frozen ACC Policies via Conformal Residual Calibration
Frozen adaptive cruise control (ACC) policies can violate constraints when deployment dynamics differ from their training conditions. We propose residual-aware conformal action filtering (RACF), which calibrates residuals of a fixed nominal predictor and converts their quantile into an operating margin for finite-model action projection. Completed transitions update margins and candidate selection without retraining the policy. In a registered comparison over 2,400 controller-trial units, Adaptive RACF achieves 94.3% episode safety, improving by 19.9 percentage points over the evaluated nominal CBF-QP baseline while reducing projection frequency from 8.11% to 6.63%. A controlled study isolates a 4.54-point improvement from residual-margin injection. In a separate matched-hardware evaluation, Adaptive reduces mean amortized rollout time by 21.2% relative to Robust CBF-QP, with 161/180 versus 170/180 safe episodes. We characterize conditions linking one-step residual coverage to constraint satisfaction and quantify the observed safety-computation trade-offs.