Generalizable Robustness Testing of DNN-Based Robotic Navigation Systems via XAI-Guided Search

Abstract

**Context:** Deep Neural Networks (DNNs) increasingly control Cyber-Physical Systems (CPSs), yet small input perturbations can cause unsafe system-level behavior. Existing approaches often optimize perturbations for individual images and evaluate them only in simulation, limiting their generalizability and practical validity. **Objectives:** This work aims to generate robustness tests that remain effective across operational observations and to evaluate whether the resulting failures transfer from simulation to a physical robot. **Methods:** We propose an explainability-guided multi-objective evolutionary approach that generates sparse perturbations over representative images selected through visual and behavioral clustering. Aggregated Integrated Gradients guide mutations toward influential image regions. We evaluate the approach on a DNN-controlled LeoRover in Gazebo, conduct an ablation study, and validate a stratified subset of perturbations on the physical robot. **Results:** The approach achieved a median success rate of 70.0%, compared with 53.85% for unguided search, and increased median hypervolume from 0.65 to 0.73. Multi-image optimization improved the success rate from 50.0% to 57.5%, while XAI guidance further increased it to 70.0%. In the sim-to-real evaluation, simulation achieved 0.95 precision and 0.67 recall, and simulated and physical failure times showed a significant positive correlation of 0.617. **Conclusion:** Combining multi-image optimization with explainability-guided search improves robustness testing for DNN-controlled robotic systems. Simulation effectively identifies and prioritizes transferable failures, but physical validation remains necessary because some real-world failures are not reproduced in simulation.