Decision-Level Multi-Sensor Coordination for Robust Navigation and High-Precision Planar Positioning of Industrial Mobile Robots

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.