Design and Application of Wireless Wall Thickness Monitoring System for Ground Testing Process

To address the issues of pipeline corrosion and erosion during ground testing, this paper presents an innovative electromagnetic ultrasonic thickness measurement system that utilizes ZigBee wireless communication technology. The system employs a ZigBee mesh topology for creating a wireless distributed network, where node devices carry out multi-point monitoring in a configuration of “one master, multiple”. Each node is powered by an STM32 embedded control chip and fitted with ultrasonic sensors. Slave nodes transmit the real-time data they collect to a server via the master node, thus enabling remote monitoring of the system through a web interface. The system incorporates an enhanced data filtering algorithm, allowing for precise monitoring of the pipeline wall thickness and providing immediate data feedback. An experimental validation of the system’s stability and long-distance transmission capabilities was performed on a simulated platform, confirming its viability and applicability for real-world engineering applications.