Sim-to-Real Reinforcement Learning for Path-Safe Target Reaching in Robotic Harvesting of Hydroponic Lettuce

Robotic harvesting requires precise manipulation to ensure accurate positioning of the end-effector, especially in a constraint workspace. This study introduces the Path-Safe Approach Proximal Policy Optimization (PSA-PPO), a target-conditioned local reaching framework designed for robotic harvesting of nutrient film technique (NFT)-hydroponic lettuce in greenhouses. The proposed PSA-PPO preserves the standard clipped PPO objective while introducing a harvesting-oriented policy formulation that integrates target-conditioned observations, corridor-aware spatial constraints, trajectory-history-based safety encoding, and task-specific success criteria for constrained robotic manipulation. PSAPPO was trained entirely in Isaac Lab and successfully transferred to a physical UR10e robotic arm without any real-world policy fine-tuning. In a controlled physical benchmark against 150 scheduled targets, PSA-PPO achieved the highest reaching rate of 94.7%, outperforming Cartesian+TOTG (86.0%), RRTConnect (88.0%), and RRT* (80.0%), while reducing median RMS jerk by 39.8 to 73.0% relative to the classical planners during the final approach segment. A formulation ablation evaluated over 200 simulation targets demonstrates that path-safety and side-corridor shaping are the principal drivers of harvesting-compatible performance: removing either term substantially degrades strict success even when terminal endpoint accuracy is preserved or improved, confirming that optimization toward the endpoint alone is an insufficient objective for constrained crop-proximal manipulation. Finally, PSA-PPO was integrated with an RGB-D vision module and an end-effector and evaluated as a complete greenhouse harvesting system across 144 lettuce harvesting attempts, achieving 94.4% vision-guided target reaching and 86.1% complete harvesting success.