Bingkun Yuan

To address the challenges of manual apple harvesting and the limitations of existing devices—such as constrained workspace, low efficiency, and limited flexibility—a two-stage, sub-region harvesting device was developed. The design, informed by the fruit distribution characteristics in densely planted dwarf apple orchards, integrates a positioning mechanism and a fruit-picking mechanism, enabling multiple pickings within a single positioning operation to enhance workspace coverage. A forward kinematics model was established using the Denavit–Hartenberg (D–H) parameter method. An improved Monte Carlo simulation based on a hybrid Beta distribution estimated the maximum reachable distances of the fruit-picking reference point in the X, Y, and Z directions as 2146 mm, 2169 mm, and 2165 mm, respectively—adequately covering the target harvesting domain. Incorporating a translational axis structure further expanded the harvesting volume by 1.165 m³, a 42.40% improvement over the conventional 3R configuration. To support adaptive control, a random point–geometry fusion method was proposed to solve for joint variables based on harvesting postures, and an automatic fruit-picking control system was implemented. Experimental validation, including reference point tracking and harvesting tests, demonstrated maximum positioning errors of 1.5 mm and 2.2 mm, a fruit-picking success rate of 76.53%, and an average picking time of 7.24 s per fruit—marking a 4.6% improvement compared to existing devices reported in previous studies. This study provides a comprehensive technical framework and practical reference for advancing mechanized apple harvesting.