Certified Gradient-Based Contact-Rich Manipulation via Smoothing-Error Reachable Tubes

Gradient-based methods can efficiently optimize controllers by leveraging differentiable simulation and physical priors. However, contact-rich manipulation remains challenging because hybrid contact dynamics often produce discontinuous or vanishing gradients. Although smoothing the dynamics can restore informative gradients, the resulting model mismatch can cause controller failures when deployed on real systems. We address this trade-off by planning with smoothed dynamics while explicitly quantifying and compensating for the induced error, providing formal guarantees on safety and task completion under the original nonsmooth dynamics. Our approach applies smoothing to both contact dynamics and contact geometry within a differentiable simulator based on convex optimization, allowing us to characterize the deviation from the nonsmooth dynamics as a set-valued discrepancy. We incorporate this discrepancy into the optimization of time-varying affine feedback policies through analytical reachable sets, enabling robust constraint satisfaction for the closed-loop hybrid system while relying solely on the informative gradients of the smoothed model. By bridging differentiable simulation with set-valued robust control, our method produces affine feedback policies that respect the unilateral nature of contact. We evaluate our method on several contact-rich tasks, including planar pushing, object rotation, and in-hand dexterous manipulation, achieving certified constraint satisfaction with lower safety violations and smaller goal errors than baseline approaches.