Fruit harvesting technologies

9. Fruit harvesting technologies

When harvesting fruits either manually or by machine, three types of activities are carried out:

  • detaching the fruit

  • collecting the detached exemplars in appropriate facilities, and, finally,

  • transporting the collected fruit first to a bigger collecting unit, then to the gathering plant.

Detachment in general is the actual separation of the harvested portion of the plant. Together with hand picking or detaching, tasks related to

  • controlling,

  • cleaning, and

  • selecting are also carried out.

Depending on whether picking is done by hand or by machine, we can speak of manual and mechanical harvesting.

Another distinction can be made depending on the type of the plant on which the fruit grows. For harvesting field fruits, fruits from bushes and from trees, different tools, aids, and machines are available.

9.1. Harvesting manually

9.1.1. Harvesting by using tools

In the course of conventional manual harvesting, several tools and mechanical aids are used.

The tools used in the field are collecting facilities and seats which make the workers’ position during picking more comfortable. For the purpose of collecting delicate fruits like strawberry, flat containers are recommended. Those may get directly on the shelves of supermarkets. The wheel seats shown on Figure 9.1 are designed for manual picking.

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Figure 9.1 Wheel picking seat

The tools used for manual picking bush and tree fruits are also simple ones. These are

  • collecting facilities, such as buckets, sacks, crates, chests or cases, bins, containers, seizers, etc.,

  • platforms and stands of different sizes, and

  • ladders.

Figure 9.2 shows a typical picking bag for delicate fruits. The inside of the metal frame is lined with a soft robber layer which prevents damage to the fruit. A hollow sac is attached to the frame which is made either of resistant woven material or of PVC. The bottom end of the sac is lifted and fixed to the frame during picking. The fruit is emptied through the sac into the container. This method avoids any impact on the fruits during emptying.

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Figure 9.2 Fruit picking bag in use during filling and emptying

(Courtesy TYROLBOX)

Manually harvested fruits from smaller containers (buckets, sacks, crates, picking bags, and the like) are then moved mainly in pallet bins. These units come in internationally standardised sizes, hence are versatile and fit into all means of transport and are rechargeable.

The platforms and stands used during fruit harvest can be classified according to their different picking heights. Figure 9.3 shows the area which an average-sized harvester person can reach. According to this Figure, the height which can be comfortably reached from the ground is between about 0.75 and 2.25 meters. In this case low stands can be used, which are only to hold the collecting facilities in a comfortable position (Figure 9.4).

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Figure 9.3 Main geometry of the hand pickers

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Figure 9.4 Low stand

Medium-height stands (Figure 9.5) are for picking fruits from heights between 2.25 and 3 meters. Those have platforms both for standing on and holding the bin.

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Figure 9.5 Medium-height stand

From high stands (Figure 9.6) workers reach fruits which are not higher than 4 meter on the tree.

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Figure 9.6 High stand

In some special cases (i.e. harvest of tropical fruits), super high stands (Figure 9.7) may be needed. Their height can be varied to a great extent. Power drive is needed to set the stand’s position, which makes them much more expensive than the ones previously discussed.

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Figure 9.7 Super high stand

Ladders are also used in the harvesting of high fruit trees. Single ladders with a stay-rod are preferred to step ladders, because the former are lighter and more stable.

Generally speaking, the higher the fruits grow the less efficient it is to harvest them. Figure 9.8 shows the yield of a conventional fruit tree as a function of height. It also shows the type of stand needed to harvest the fruits of this tree.

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Figure 9.8 The distribution of the yield in the canopy

9.1.2 Harvesting with mechanical aids

The collection and delivery of manually harvested fruits from the tree to the pallet bins are done either by hand or using mechanical aids. Before showing practical examples for both, first the organisation of manual harvesting should be discussed.

The following transport activities are part of the harvest:

  • transport of empty pallet bins from their storage to the location of filling (in most cases, mechanised),

  • transport of the filled pallet bins to a transfer point where they may be stacked (in most cases, mechanised), and

  • transport of pallet bins from the transfer point to the operation area /warehouse (mechanised).

The two most common harvesting technologies in manual harvesting are:

  1. the distribution of pallet bins in the orchard prior to, and their collection after, the harvest and

  2. the use of mobile harvesting cars/trailers and platforms.

1. The distribution of the pallet bins prior to harvesting in the orchard requires mechanical transporters or hand-operated trailers.

In order to calculate the distance between the pallet bins in the row, the yield must be estimated. Because of large differences from tree to tree, the number of bins must be about 10% more than really needed.

The equipment used for pallet bin transport ranges from man-operated tools to self-propelled machines. Figure 9.9 shows a one-man operated, two-wheel pallet carrier developed for the smallest orchards.

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Figure 9.9 One-man operated, two-wheel pallet carriers

Low profile, tractor-mounted forklifts are recommended for small horticultural enterprises (Figure 9.10). The forklifts’ transport capacity is one pallet bin, and their lifting height is about 50 cm.

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Figure 9.10 Low profile, tractor-mounted forklift

Some tractor-towed trailers have a capacity of 3 pallet bins. The trailer on Figure 9.11, due to its U shape frame, can approach the bins in reverse, fix each of them with 4 iron bolts, and lift and sink them via hydraulic cylinders. On the trailer seen on the video, the iron bolts are replaced by curved iron tubes which enable the automatic pick-up and release of pallet bins simply by lifting and sinking of the U shape frame.

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Figure and video 9.11 Tractor-towed self-loading/unloading trailer for three pallet bins

1.: U shape frame, 2.: rear wheel, 3.:lifting mechanism

The self-propelled pallet bin transporters are designed for carrying 6 pallet bins at the same time. They are able to load and unload the bins automatically.

The machine shown on Figure 9.12 has a lifting unit in the front, supplied with four vertical arms. They end in strong, horizontal bolts. The distance between the arms on the left-hand and right-hand side can be changed hydraulically. During pickup the machine stops in front of the bin, sinks the lift with its arms in the widest position. Then the arms close and the lift takes off the bin. Thereafter, a plate slides out of the main frame below the pallet bin. The lift sinks the bin onto the plate and releases it. The plate slides back in between the main frames while the powered chain conveyors on the top of the frames (Figure 13) carry it farther backwards.

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Figure 9.12 Self-propelled pallet bin carrier with a lift in the front

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Figure 9.13 The powered chain conveyor on the top of the main frame to transport the bins

This procedure is repeated until 5 bins are on the machine’s chain conveyor and the 6th is held by the lift. During unloading the back extensions are sloped and the powered chain conveyors move them to the ground.

The carrier is driven hydrostatically which ensures a wide variety of speed and good manoeuvrability.

Another pickup principle is realised on the self-propelled bin carrier shown on Figure 9.14. It takes off the pallet bins without stopping. Its front extensions are supplied with powered chain conveyor and so are the main frames. When approaching a bin, the front extensions are sloped so they can get underneath the pallet. As the machine moves forward, the powered chains tilt the bin and pick it up.

This carrier is also hydrostatically driven and is able to carry 5+1 pallet bins (one on the front extensions).

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Figure 9.14 Self-propelled bin carrier with powered chain conveyor on the front extensions

2. Using mobile harvesting cars/trailers and platforms in manual harvesting means that the chests, bins, cases or pallet bins continuously move in the field or along the orchard row in accordance with the speed of the manual harvesting.

Electrically driven pallet bin carriers are offered for small orchards (Figure 9.15). The loading of empty pallets is done manually. The full pallet bins are unloaded after the tilting platform of the carrier has been released.

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Figure 9.15 Pallet bin carrier with electric drive developed for small orchards

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Figure 9.16 Self-propelled harvesting platform with conveyor belts

The self-propelled machine on Figure 9.16 was developed for harvesting field fruits or vegetables. The fruits are packed in boxes and left behind for collection later.

In orchards, mobile harvesting trailers, also called conveyor trailers, may be used (Figure 9.17). They are tractor-towed and are able to carry 5 pallet bins.

The pickers work beside the trailer and use collecting facilities, platforms, and ladders. The pickers are organised in four groups, and each group fills its own bin. The 5th bin is to compensate for the difference in working capacities.

The loading of empty pallet bins and unloading of filled ones are done by tilting the platform by the tractor’s 3 point hitch.

These trailers have a very simple construction, as they have no lights or breaks. They are designed only for orchard use. Although they are relatively cheap, they need a tractor for their operation. This way the power capacity of the tractor is not utilized well . This may be the reason for the recent wide-spread use of self-propelled harvesting platforms.

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Figure 9.17 Tractor-towed harvesting trailer for carrying 5 pallet bins

Self-propelled harvesting platforms are able to carry both the pallet bins and the workers in the orchards. There is a wide variety of this equipment on the market, ranging from machines operated by 2 to 8 workers, from electric to diesel engine powered versions.

The platform on Figure 9.18 is an electrically driven machine with 2 pickers travelling on the platform. At the beginning of the work, it carries 4 empty pallet bins and leaves the filled ones in the row. The workers collect the picked fruits in their baskets which will be then lowered into the bin when emptying. Two additional pickers can harvest from the ground walking alongside of the unit and putting the fruits directly into the bin.

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Figure 9.18 Electrically driven self-propelled harvesting platform

Up to eight pickers can work on the self-propelled platform shown on Figure 9.19. It is made by the same company which manufactures the product shown on Figure 9.12. The method of loading empty bins and unloading the filled ones is identical to the method used by the other machine. The differences are in the additional picking platforms with two picking heights and in the internal lift for the bins.

As Figure 9.19 shows, the previously distributed empty pallet bins will be picked up from the orchard row and elevated by the internal lift to the two picking platforms. The picked fruit will be collected either directly into the bins or into a picking bag firs. After the pallet bins have been filled, the internal lift lowers them to the main frame. From there the powered chain conveyor delivers them to the back extensions.

The width of the platform is adjustable to the distance between the limbs in the row.

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Figure 9.19 Self-propelled platform for 8 workers

The self-propelled platform shown on Figure 9.20 handles empty and filled pallet bins in a manner similar to that of the machine shown on Figure 9.18. A special high platform trailer towed by the basic unit carries the empty standard cases. These can be placed on the rotating bin filling unit by the back extensions of the self-propelled platform.

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Figure 9.20 Method of handling empty and filled pallet bins by a self-propelled platform

The platform consists of a sloped central conveyor, 6 electrically or mechanically driven small conveyor belts, different height platforms for the worker, a bin filling unit, the engine, drive, and wheels (Figure and video 9.21).

The sloped central conveyor collects the fruit picked by hand and placed on the small conveyor belts.

The workers can easily set the small conveyor belts in the best position (the belts can be turned and sloped independently).

The platforms for the workers are positioned at two different levels so that all 6 workers (3 on each side) can work with the machine: 4 of them on the platforms and 2 walking in front of it.

The Figure 9.21 shows a smaller version at which only two platforms are available for two workers.

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Figure and video 9.21 The mobile platform and the bin filling unit

The bin filling unit (Central and right in Figure 9.21) has to deliver the fruit from the central conveyor into the pallet bin gently enough to avoid any bruises. To achieve this, during filling, the bins are turned around their imaginary vertical axle. The bins have to be square shaped. The rubber fingers fixed to the vertical conveyor belt take the fruits from the central conveyor and lower them slowly into the bin on top of the other fruits. The conveyor belt rises automatically as the fruit layer in the bin increases. A tilting plate at the bottom end of the conveyor belt serves as a sensor. When the plate contacts any fruit in the rotating bin, it will be lifted and a signal is given to raise the conveyor. It stops when there is no more contact between the plate and the fruit.

When the bin is filled, the turning plate is tilted and the bin slides down to the ground. Afterwards, it is replaced by an empty bin from the trailer behind.

This machine is driven mechanically or hydrostatically and is powered by a small diesel or Otto engine. Of the 3 wheels, the frontal one is steered by one of the pickers working on the ground or on the platform.

Self-propelled harvesting platforms can increase the workers’ capacity in an apple harvest up to 350 kg/h. In addition, they are versatile in application, since they can be used as pruning stands, stands for installation of dispensers, for manual thinning, etc.

9.2. Harvesting by machines

As said before, mechanical harvesting means detaching, collecting and transporting fruits by machines.

Detaching can be performed by contacting the fruit directly or by vibrating the plant. Because of risk of damage, at present, only small fruits (berry fruits, almonds, nuts, sweet and sour cherry, plums) or fruits for direct processing (apples, apricots) are mechanically harvested.

It must be mentioned that harvesting with robots makes possible that even delicate fruit can be gently picked.

9.2.1. Harvesting by direct contacting

Harvesting by combing

Mechanical harvesting by contacting the fruit directly can be performed in many ways. One method is combing off the fruit. Figure 9.22 shows an experimental machine for apples grown on hedge. Rubber fingers are fixed to belts and are driven in accordance with the forward speed so they move through the hedge vertically from the bottom to the top. The apples are picked by two neighbouring fingers. Upon meeting obstacles (like strong branches), the fingers bend back.

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Figure 9.22 Experimental apple harvester

Harvesting by cutting and forwarding by a header

The method of harvesting of strawberry by mowing the plant and picking it up by a header unit may be considered also as one of the direct methods, since the header unit contacts and forwards the fruits during cutting (Figure 23). The cutter bar cuts the stems with the fruit still on them. The free leaves are blown away by a cross-flow fan. Two axial flow fans placed below the wire mesh conveyor straighten the fruit stems to be removed by two singulators (rotating knives). At the end, the strawberries are collected in trays and are processed soon afterwards.

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Figure 23 Strawberry harvester with cutter bar and singulators

9.2.2 Vibrating harvesting of the fruit

By vibrating the branches, limbs or trunks of the fruit trees or the bushes, the fruit swings, turns and/or twists along its stem which leads to its detachment. Many factors such as the vibration’s frequency and amplitude, the participating masses, the length of stems, and others influence the process.

In order to understand the effect of the factors influencing removal, researchers created a simple model for both the harvesting machine and the plant. It is the Poynting-Thomson model, coupled with an eccentric mass inertia shaker (Figure 9.24).

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Figure 9.24 Poynting-Thomson model, coupled with an eccentric mass inertia shaker

The differential equation of the model is:

keplet1(1)

where: Mt is the total mass of the limb-shaker system in kg (Mt =MM+M +m) ; is the limb acceleration in ms-2; k is the viscous damping coefficient of the limb in Nsm -1; is the limb velocity in ms-1; c is the apparent spring constant of the limb in mN-1; is the limb displacements in horizontal direction in m; m is the total unbalanced mass of the shaker in kg; r is the eccentricity of the unbalanced masses in m; ω is the shaking frequency in rad s-1; t is the time in s.

Following from Eqn. 1 the momentary power demand for a rotating type shaker shown on Figure 9.24:

keplet2(2)

where: X is the amplitude of displacement in horizontal direction in m; and is the phase angle in rad.

For the calculation of the trunk displacement amplitude X, the following equation can be used:

keplet3(3)

and for the phase angle:

keplet4(4)

The phase angle indicates the position of the forces acting during vibration. As the position of the centrifugal force changes its direction, thedisplacement, velocity and acceleration of the system change accordingly. Figure 9.25 shows the direction of the inertia, elastic and damping forces being the function of acceleration, displacement and velocity respectively, when.

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Figure 9.25 The balance of the forces acting and reacting during shaking

Eqn. 2 for the power demand of the shaker consists of two parts. The first part is a sinusoidal function having its maximum twice in a period, resulting in 0 power demand.

The second part is constant and is influenced by all the characteristics shown on Figure 9.24. Depending on the height of shaking on the tree, the values MM, c and k are changing.

In regard to the Eqns. 1, 2, 3, and 4, the following statements can be made:

  • The limb amplitude can be influenced most by the masses m and M and the eccentricity r of the shaker machine

  • The machine-tree system on the Figure 9.24 has a resonant frequency at which the amplitude is the highest. It is influenced by all the factors mentioned before and therefore it can be influenced by the machine’s characteristics

  • Best efficiency is to be expected when shaking on the resonant frequency

In case of a vibrating spokes shaker (like for berry fruits, Figure 9.38), Eqns. 1-4 apply also, as the rotation can be transferred to translation.

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    Figure 9.26 The rotation of a vibrating spokes shaker transferred to translation

    Reducing the tree-shaker connection (Figure 9.24) to a two mass system, the amplitude X of the shaken tree trunk or main branch can be estimated as follows:

     keplet55.

    Where, as said before, m is the eccentric mass of the shaker, Mt is the total mass of the system, including the eccentric mass m, the mass of the machine frame and the reduced tree mass.

    Equation 5 applies also to the vibrating spokes shaker. It indicates how the shaken plant mass influences the amplitude of the spokes.

    The usual output of inertia shakers is a relatively high frequency vibration (10–40 Hz), and a short stroke (5–20 mm) delivered to the tree. As a result of these, the following typical amplitudes are generated. For cherries and sour cherries: 15-30 mm, for prunes: 10-15 mm, for olives: 50-60 mm and for apricots 10-15 mm.

    For the estimation of the removal relative to the yield produced in a harvest by shaking Fridley and Adrian, 1966 recommend the following empirical equation:

    Where S is the peak to peak stroke of the shaken tree, ω is the angular velocity of the shaker drive, a,b and c are empirical constants, characteristic of the fruit tree variety.

    9.2.2.1 Inertia type shaker machines

    Trunk shakers are the most efficient vibratory harvesters as each tree is shaken only once (see also Figure 9.24).

    The structure of a trunk shaker can be seen on Figure 9.27. The machine is tractor-mounted or self-propelled, although its motion is independent of its carrier.

    In case of some shakers, the angular velocities ω1 and ω2 of the rotating eccentric masses are different. If ω1 = - ω2 the displacement during shaking is unidirectional. If ω1 = ω2 the displacement is circular, and if ω1 ≠ ω 2 the displacement is multi-directional.

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    Figure 9.27 Amplitude patterns of a trunk shaker. 1.: hydraulic motors, 2.: eccentric masses, 3.: jowls to grip the trunk, 4.: hydraulic cylinder to close the jowls.

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    Figure 9.28 Self-propelled trunk shaker with a wrap-around catching surface

    Beam shakers are connected to the main limbs or the trunk of younger trees (Figure 9.29). The shaking of main branches results in a higher detachment rate, but takes more time compared to the shaking of the trunk. The same equations and statements apply to the beam shakers as to the trunk shakers, although on the version shown on Figures 9.29 and 9.30 the mass m swings along the beam instead of turning.

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    Figure 9.29 Model of beam shaker and fruit tree

     

    9.2.2.2 Cable shakers

    Cable shakers are the simplest and cheapest limb shakers. The tractor-mounted adapter on Figure 9.31 consists of a PTO driven eccentric bolt and a cable, one end of which is fixed to the bolt, the other to the limb.

    As the cable only pulls the limb, the elastic force of the tree has to return it. This means that the frequency of shaking must not be higher than the resonance frequency of the limb.

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    Figure 9.31 Cable shaker with eccentric bolt

    1.,2.: drive of the eccentric bolt, 3.: bolt, 4.:cable disc, 5.: cable, 6.: cable connecting device, 7.:limb

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    Figure 9.32 Cable shaker driven by the PTO through a tilting mechanism (left). Fixing the cable to the limb (right).

    Shaker-clamps

    Shaker-clamps must be carefully applied, since the significant shaking force is transmitted to the tree at their attachment. It can lead to tree injuries when the basic rules are ignored during shaking. Bark injuries can be avoided on the one hand by reducing the surface pressure. On most machines, this can be solved by changing the pressure in the hydraulic cylinder which closes the clamp. On the other hand, the clamp must be perpendicularly attached to the trunk or the main branch. This applies first of all to boom shakers.

    Shaker-clamps consist of jaws; at least one of those is movable by hydraulic cylinder. Their contacting surface is soft. In some cases, it consists of two layers. Grease is put between the layers to reduce shear stress on the bark.

    9.2.3 Catching surfaces

    Catching surfaces for collecting the detached fruits constitute a part of shaker machines. In addition to the wrap-around catching surface (Figure 9.28), many other types are used (Figure 9.33). In some cases, they consist of two components. One component is carried by the shaker machine, the other by a separate self-propelled unit. The catching surface unit contains a fan for getting rid of light impurities and a carries a replaceable pallet bin.

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    Figure 9.33 Different types of catching surfaces

    9.2.4 Pickup of fruits from the ground

    Where there is no risk of damage or damage has little importance as in case of fruit like almonds, walnuts, or apples for juice production, harvesting can be done by the so-called shaking without catching technology. The shaken fruits are first swept in between the rows than a pickup harvester lifts them from the ground. Figure 9.34 shows a cylindrical auger sweeper, while on Figure 9.35 the sketch of a self-propelled pickup machine can be seen. In order for the pickup technology to work, the ground must be kept even, the machines have to be low enough to get underneath the limb.

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    Figure 9.34 Cylindrical auger sweeper used before picking up the fruit

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    Figure 9.35 Self-propelled pickup harvester

    The man-operated pickup unit on Figure 9.36 was developed for small orchards. The wooden roller is supplied with steel nails which pierce the fruits and lift them from the ground. Afterwards a comb removes and guides the fruits into the collecting buckets.

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    Figure 9.36 Hand-pushed pickup device for collecting fruits from the ground

    9.2.5 Mechanical harvesting of bush fruits

    For berry fruit harvesting, mainly vibrating spokes shakers are used. The inertia-type shaking unit consists of an axle with spokes attached and a driving mechanism (Figure 9.37). In the latter, two eccentric masses m are rotating in the same direction and with the same ω angular velocity. Their eccentricity is r, their distance from the centre line is R. The resulting centrifugal force is .

    In position a. on Figure 37, where r and R are in one line, the centrifugal forces annul each other. If the arms r turn further (position b.), a torque arises which turns the axles with the spokes clockwise. After turning 1800, the direction of torque changes. This results in the vibration of the axle.

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    Figure 9.37 The driving mechanism of the inertia type vibrating spokes shaker

    Depending on the plant’s growing system, the shaker units can be positioned either in a V shape or in a horizontal arrangement. Figure 9.38 shows a machine with shakers in V shape. The harvester separates the shrubs, then 2 shaker units detach the berries on each side. The fruits fall onto the catching conveyor and will be delivered into the bins.

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    Figure 9.38 Berry fruit harvester with shakers in V shape

    1.: shaker units, 2.: brunch lifting bodies, 3.: shrub separating body, 4.: berry catching conveyor, 5.: bin filling conveyors, 6.: bins, 7.: fans to blow away the leaves

    The shaker units of the berry fruit harvester on Figure 9.39 are in a horizontal position. The two units shake the horizontal branches of the plant and a conveyor belt underneath collects the detached berries. They will be then be cleaned and manually sorted.

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    Figure 9.39 Raspberry harvester designed for horizontal canopy

    It is important to notice that the shaker units on both machines turn freely as the machine advances. Accordingly, their motion is dual: they rotate and vibrate at the same time.

    9.3. Transport of pallet bins on the road

    In large orchards, special trailers are used to transport the bins from the transfer point to the operation area /warehouse. Some of these trailers are able to carry up to 48 pallet bins at the same time. Prior to the self-loading and unloading of the trailers, the bins have to be stacked on skids (Figure 9.40).

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    Figure 9.40 Block of containers stacked on skids

    Tractor-mounted forklifts or front loaders are used for the purpose of stacking the bins (Figure 9.41 and 9.42).

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    Figure 9.41 Tractor-mounted forklift

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    Figure 9.42 Front loader with forks

    A special trailer for stacked bins is shown on Figure 9.43. It consists of a frame which is open in the back. Four consoles hang from the frame, two on each side. To the bottom of each console, a strong rail is connected through screw-type actuators.

    During self-loading, the left and right hand side consoles are in their farthest position from each other and the rails are lowered. Then the trailer reverses to the point where the stacked bins get in-between the rails. Now the consoles are moved to the centre and the rails are lifted. The block of bins can be transported now on the road. Unloading happens the opposite way.

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    Figure 9.43 A special trailer for stacked bins

     

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