Need help running expect script under CYGWIN...

Hi, much thanks in advance for any and all help anyone can provide.  

I'm by no means a scripting/*NIX/Expect guru - but a while back was able to stumble  through setting up Windows/CYGWIN/expect enough to put together a really functional system for basic network management of Cisco routers and switches.  Everything ran fine on my old laptop which died recently.  I've just downloaded the latest CYGWIN to my new laptop (I'm assuming a newer version since last July) and none of my scripts will work any longer.  They are very basic - essentially they just spawn telnet to a host and do what's in the script.  It appears that with the current version of CYGWIN (or the expect that runs in it) the spawn sessions are dying early.  I've scoured the internet for help, but while there are several people in my same boat - I'm not finding any solutions.  Attached below is my error message, my expect script, and my (simple) shell script that pipes in a list of names/IPs as arguments to expect.

I really relied on this to manage a large number of switches in the past and am really hurting not having this - thanks for any input at all.

-Calvin

ERROR:
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Spawn telnet pn-abrams-switch
Send: invalid spawn id (4)

EXPECT SCRIPT:
=================================

set timeout 20
set USER_NAME "XXXXX"
set USER_PASS "XXXXXX"
set ENABLE_PASS "XXXXXX"
set ROUTER $argv
spawn telnet $ROUTER
expect "Username: "
send "$USER_NAME\r"
expect "Password: "
send "$USER_PASS\r"
expect "#$"
send "term length 0\r"
expect "#$"
log_file ./output/$ROUTER-show_run.txt
send "sh run | include hostname\r"
expect "#$"
send "\r"
expect "#$"
send "\r"
expect "#$"
send "sh run"
expect "#$"
send "\r"
expect "#$"
log_file
send "exit\r"

SHELL SCRIPT:
===================================

for ROUTER in `cat names.txt`; do ./expect-BABW-show_run.txt $ROUTER; done