The verification of aerospace structures, including full-scale fatigue and static test programs, is essential for structure strength design and evaluation. However, the current overall ground strength testing systems employ a large number of wires for communication among sensors and data acquisition facilities. The centralized data processing makes test programs lack efficiency and intelligence. Wireless sensor network (WSN) technology might be expected to address the limitations of cable-based aeronautical ground testing systems. This paper presents a wireless sensor network based aircraft strength testing (AST) system design and its evaluation on a real aircraft specimen. In this paper, a miniature, high-precision, and shock-proof wireless sensor node is designed for multi-channel strain gauge signal conditioning and monitoring. A cluster-star network topology protocol and application layer interface are designed in detail. To verify the functionality of the designed wireless sensor network for strength testing capability, a multi-point WSN based AST system is developed for static testing of a real aircraft undercarriage. Based on the designed wireless sensor nodes, the wireless sensor network is deployed to gather, process, and transmit strain gauge signals and monitor results under different static test loads. This paper shows the efficiency of the wireless sensor network based AST system, compared to a conventional AST system.
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