Since it's been a while and no one has replied yet, I figured I'd offer some general advice which might make it easier for others to offer specific help:

• Post your exact actual output.
• Post your expected output.
• Reduce your code as much as possible while still reproducing your error condition. Do you really need those 20 lines for $ARGV?
• If Expect has any error/status methods, try using them to get more info (Tip #11 from Basic debugging checklist).
• The proper link is Expect command output parser sub (see What shortcuts can I use for linking to other information?)