Design of a Multi‐Sensor Integrated Control System for Vehicle‐Mounted Tunnel Lining Inspection With Real‐Time Velocity and Posture Tracking

ABSTRACT This study presents a holistically integrated multi‐sensor control system for vehicle‐mounted tunnel lining inspection, seamlessly combining Automated Track Vehicle (ATV) technology with robotic‐arm posture tracking within a synergistic framework. The system achieves automated velocity regulation and millimeter‐level positioning accuracy, significantly enhancing inspection efficiency and operational safety. Key innovations include: (1) a coupled kinematic/dynamic model of the vehicle‐arm system to capture motion coupling effects; (2) an optimized feedback control architecture incorporating an Auto‐Disturbance Rejection Controller (ADRC) with detailed design, tuning, and stability analysis; (3) real‐time data transmission via industrial Ethernet and the Modbus/TCP protocol (with average latency 1.54 ms, ≤ 2 ms); (4) a multi‐sensor fusion logic based on extended Kalman filter (EKF) for dynamic posture correction. Experimental validation confirms that the system maintains a dynamic deviation of ≤ 8 mm/s at operational speeds of 1–5 km/h, keeps the antenna‐to‐lining distance at 100 ± 20 mm, and ensures Ground Penetrating Radar (GPR) signal integrity at standoff distances ≤ 0.25 m. This research establishes a robust technological foundation for next‐generation autonomous tunnel inspection systems and represents a significant advancement in the robustness of non‐destructive testing methodologies for critical infrastructure.