This paper addresses the energy-inefficiency problem of four-degrees-of-freedom (4-DOF) hydraulic manipulators through redundancy resolution in robotic closed-loop controlled applications. Because conventional methods typically are local and have poor performance for resolving redundancy with respect to minimum hydraulic energy consumption, global energy-optimal redundancy resolution is proposed at the valve-controlled actuator and hydraulic power system interaction level. The energy consumption of the widely popular valve-controlled load-sensing (LS) and constant-pressure (CP) systems is effectively minimised through cost functions formulated in a discrete-time dynamic programming (DP) approach with minimum state representation. A prescribed end-effector path and important actuator constraints at the position, velocity and acceleration levels are also satisfied in the solution. Extensive field experiments performed on a forestry hydraulic manipulator demonstrate the performance of the proposed solution. Approximately 15–30% greater hydraulic energy consumption was observed with the conventional methods in the LS and CP systems. These results encourage energy-optimal redundancy resolution in future robotic applications of hydraulic manipulators.
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