Influenced by the maturity and material properties, fresh corn has problems, such as low picking rate, high energy consumption and high damage rate during mechanized harvesting. For the above problems, a bionic reverse picking header was designed using the post-ripening morphology of corn and the hand-picking behavior as bionic prototypes. Model analysis and structural design of the key components of the header, including the reeling device, clamping device and picking device, were carried out. Based on the designed header prototype, single-factor tests and Box Behnken tests were conducted to explore the factors affecting the working performance of the picking header. The optimal structural parameters and working parameters were determined by response surface method. The results showed that with the increase in the clamping picking device speed and the stalk feeding speed, the picking rate first increased and then decreased. The interaction between feeding speed and cutter position had the most significant effect on the picking rate. The unique reverse picking mechanism and flexible device of the header could avoid collision and damage to the corn ears. The highest picking rate was achieved when the clamping picking device speed was 416.81 rpm, the stalk feeding speed was 1.13 m/s, and the cutter position was −5.45 cm.

A new bending fracture principle is proposed for ear picking by simulating the process of manually breaking off corn cobs. Based on this, a new test device for corn ear picking was designed to obtain the relationship between the ear-picking rate and the rotational speed of the snapping rollers, as well as the feeding speed. A mechanical test was conducted on corn at two different harvesting stages. This proved that the tensile breaking force used in ear picking was considerably greater than that associated with bending fracture, regardless of whether it was silage or mature corn. Moreover, the feasibility of the working principle of the bending fracture was tentatively verified by a verification test. Then, ear picking could be achieved using the designed device with less damage occurring to the corn ears and straw, according to the test for corn ear picking. Finally, a range analysis showed that the highest ear-picking rate could be obtained by the test device at a snapping roller rate of 780 r/min and a feeding speed of 1.5 (m/s), with a 40° angle between the snapping rollers and conveyor. Thus, this study provides a reference for the further development of a corn harvester for silage.