Vertical farming integrated with hydroponics offers sustainable urban food solutions, yet reliance on manual harvesting, which requires labour-intensive tray transport and cutting, hinders scalability. This study focuses on the design and performance testing of an end effector for automated in-situ robotic harvesting of vertically stacked hydroponic lettuce, addressing two critical advancements: mechanised harvesting and post-harvest lightweight tray logistics. Manual harvesting trials revealed that push-cutting requires only 3.154 N of force (approximately 66 % lower than pull-cutting's 9.313 N), forming the basis for an energy-efficient end effector design. A novel robotic harvesting mode based on push-cutting was proposed, incorporating five phases: inserting, gripping, cutting, transporting, and unloading. An end effector integrating gripping and cutting functions was designed and optimised. Using response surface methodology, the optimal gripper parameters were determined: rotation radius of 73 mm, rotation angle of 80°, and movable finger diameter of 25 mm. The cutting performance test revealed the optimal cutting position as 5 mm above the root-stem junction and the optimal bevel cutting angle as 15°. Through structural improvements, the end effector was enhanced with a two-finger rotation mechanism to achieve more efficient and convenient unloading. Experimental results from performance testing demonstrated a harvesting success rate of 94 % and a leaf loss rate of 3.50 %, confirming the effectiveness and feasibility of the designed end effector. This innovation establishes a logistics-minimised automation framework for vertical farms, enhancing scalability and sustainability through energy-efficient, high-precision robotics and optimised material flow.
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