ArticleSensors (Basel, Switzerland)2026
Decision-Level Multi-Sensor Coordination for Robust Navigation and High-Precision Planar Positioning of Industrial Mobile Robots.
Article in Sensors (Basel, Switzerland), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
High-precision manufacturing in unstructured factories imposes stringent requirements on real-time scene perception and end-effector positioning accuracy. Traditional single-sensor solutions suffer from perception blind spots in human-robot mixed environments with complex lighting, while chassis cumulative error often leads to rigid collisions during end-effector operations. To address this, this paper proposes and evaluates a decision-level multi-sensor coordination mechanism for robust navigation and high-precision planar positioning of industrial mobile robots. The mechanism assigns explicit sensor roles, distance-dependent trigger conditions, and deterministic safety priorities. At the navigation and obstacle avoidance level, a sequential decision policy is constructed: macroscopically, a lightweight You Only Look Once version 5 small (YOLOv5s) is utilized for the early detection of dynamic objects, providing bounding-box coordinates to trigger preemptive deceleration, while LiDAR independently provides geometric ranging for ROS local-costmap updating and detour replanning; microscopically, a low-level hardware interrupt strategy triggered by ultrasonic sensors is proposed to mitigate near-field blind spots and reduce communication latency. At the end-effector positioning level, under illumination conditions ranging from 200 to 1000 lux, an adaptive alignment algorithm combining hue-saturation-value color-space morphological processing and Kalman filtering is proposed to suppress measurement noise caused by illumination variations and mechanical vibrations. Experiments in the tested dynamic human-robot mixed scenarios showed no rigid collisions for the proposed system and an emergency response time of approximately 50 ms against sudden blind-spot intrusions. Simultaneously, the system achieves a 95% reliability rate in controlling the end-effector 2D planar positioning error (X-Y plane) within a ±2 mm tolerance under complex illumination interference. These results demonstrate improved navigation safety and planar-positioning reliability under the tested flexible-manufacturing conditions.
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