Hierarchical Redundancy-Driven Real-Time Replanning for Manipulators Under Dynamic Environments and Task Constraints

Redundant robot manipulators are widely used in constrained operations and tasks in complex environments. However, when multiple task constraints and inequality constraints coexist, motion planning becomes significantly more difficult. In high-dimensional configuration spaces, conventional planners are prone to local minima and may generate trajectories that are difficult to execute in real time. To address these issues, this paper proposes a hierarchical, redundancy-driven real-time replanning framework. First, we perform Cartesian sampling on the task-constraint manifold to reduce the search dimension and generate multiple candidate joint configurations for each Cartesian sample via a redundancy mapping. During connection, manipulability and executability margin are used as evaluation metrics, so that redundant degrees of freedom are explicitly exploited in tree expansion and configuration selection. Second, at the local execution layer, we employ a null-space manipulability optimization strategy to continuously improve dexterity while keeping the primary task unchanged and combine it with a priority-based hard inequality constraint filtering mechanism to project the nominal motion onto the feasible set under joint limits, velocity bounds, and safety-distance constraints in real time. Unlike existing approaches that treat global planning and local control as loosely coupled modules, the proposed framework unifies redundancy reconfiguration, feasibility maintenance, and topological replanning within a single closed-loop structure, thereby reinterpreting local minima as event-triggered topology-switching conditions. To handle the mismatch between dynamic environments and real-time perception, we further introduce a feasibility-margin monitoring mechanism that triggers event-based replanning based on changes in manipulability, constraint scaling, and safety distance, enabling fast topology-level switching and escape from local minima. Simulation and experimental results show that the proposed method effectively restores manipulability through redundancy-driven configuration adjustment and achieves a higher success rate of local recovery under dynamic obstacle intrusion. In forced replanning scenarios, the framework further demonstrates faster environmental response and lower replanning overhead while maintaining better task-constraint stability compared with existing approaches.