Performance Evaluation and Error Mitigation of Ultrasonic Indoor Positioning: An ESP32-Based IMU-ESKF Architecture

Reliable indoor localization is required for automated guided vehicles (AGVs), robot validation, and industrial digital-twin applications, but ultrasonic positioning can degrade sharply when acoustic visibility changes. This paper evaluates Marvelmind Super-Beacon localization in controlled laboratory experiments involving both AGV tracking and UR10 robot-arm positioning. The non-inverse architecture (NIA) and inverse architecture (IA) configurations are included as parallel validation scenarios to assess the robustness of the proposed mitigation framework across different Marvelmind deployment modes. The baseline analysis identifies the dominant acoustic failure modes, including multipath-induced scatter, crossover-zone handover jumps, update-rate degradation, complete non-line-of-sight (NLoS) outages, and height-dependent 3D jitter. To mitigate these effects, an embedded ultrasonic–inertial pipeline is implemented on an ESP32-S3-WROOM-1 module. The system combines UART packet validation, interrupt-driven ICM-20948 inertial acquisition at 500 Hz, sliding-window kinematic outlier rejection, and a 15-state error-state Kalman filter (ESKF). The embedded estimator logic is designed to maintain motion continuity during intermittent or corrupted acoustic positioning while reintroducing validated ultrasonic absolute corrections. Using recorded AGV and UR10 datasets, mitigation performance was quantitatively assessed through a firmware-consistent replay of the recorded measurements, using the same gating, inertial propagation, and measurement-update logic as the real-time ESP32-S3 implementation. Across ten trials per configuration, the replay-based trial-mean RMSE in the 2D AGV scenarios decreased from 101.2–104.1 mm for raw ultrasonic data to 47.2–48.7 mm after fusion, while peak failure-interval errors were reduced by 64.2–65.7%. In the 3D UR10 scenarios, replay-based trial-mean RMSE decreased from 157.6–158.4 mm to 80.2–80.5 mm, and peak height-sensitive 3D errors were reduced by 58.8–60.0%. The results demonstrate the feasibility of embedded ultrasonic–inertial robustness enhancement for localization in controlled laboratory AGV and robot-arm scenarios. While the proposed approach shows promising performance under the investigated conditions, further validation is required before extending the conclusions to larger-scale and dynamically changing industrial environments. Full closed-loop online robot localization and control based directly on the fused localization output remain subjects for future investigation.