Design and Integration of a Wireless Stretchable Multimodal Sensor Network in a Composite Wing

Area of Science:

• Materials Science and Engineering
• Electrical Engineering
• Sensor Technology

Background:

• Real-time distributed sensing and remote monitoring require advanced sensor networks.
• Existing stretchable sensors often face challenges in signal quality and manufacturing scalability.
• Aerospace applications demand robust, high-accuracy sensing solutions integrated into structural components.

Purpose of the Study:

• To develop a stretchable sensor network with high signal-to-noise ratio and measurement accuracy.
• To create a novel, high-yield, low-cost manufacturing process for stretchable sensor networks.
• To integrate various sensor types (PZT, SG, RTD) and associated electronics for comprehensive monitoring.

Main Methods:

• Designed an island-and-serpentine network architecture with 17 distributed sensing nodes.
• Developed a novel high-yield manufacturing process on recyclable wafers.
• Integrated signal conditioning, data acquisition, and wireless transmission electronics into a flexible frame.
• Utilized an automated stretch machine for network expansion and laminated the network into an aerospace composite wing.

Main Results:

• Achieved a stretchable sensor network with high signal-to-noise ratio and measurement accuracy.
• Successfully fabricated the network using a novel, low-cost, high-yield manufacturing process.
• Demonstrated simultaneous sampling for PZT sensors for impact detection and successful integration into an aerospace composite wing.
• Developed and configured firmware/software for correct system operation and real-time data display.

Conclusions:

• The developed stretchable sensor network offers a robust solution for real-time distributed sensing and remote monitoring.
• The novel manufacturing process enables cost-effective, scalable production of advanced sensor networks.
• Successful integration into an aerospace composite wing highlights the system's potential for structural health monitoring and other demanding applications.