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現(xiàn)代航空發(fā)動(dòng)機(jī)正朝著高溫、高壓、高轉(zhuǎn)速的方向發(fā)展［1］，其上愈加惡劣的工作環(huán)境不可避免地對(duì)數(shù)控系統(tǒng)中傳感器的穩(wěn)定工作產(chǎn)生不利影響，導(dǎo)致傳感器故障發(fā)生，進(jìn)而干擾控制系統(tǒng)使發(fā)動(dòng)機(jī)性能下降［2］。因此，提高傳感器的可靠性對(duì)發(fā)動(dòng)機(jī)安全、可靠工作極為重要。通過對(duì)傳感器故障件的科學(xué)診斷，探索其失效機(jī)理，將有利于傳感器的迭代設(shè)計(jì)，進(jìn)而不斷提升可靠性。傳統(tǒng)的傳感器故障檢測(cè)方法存在下列局限性: 1) 無(wú)損檢測(cè)時(shí)，一般采用 X 射線機(jī)，僅適用于對(duì)傳感器的金屬結(jié)構(gòu)進(jìn)行觀察，非金屬部分無(wú)法清晰顯現(xiàn)。且一般只能二維成像，無(wú)法三維立體顯示。2)破壞性觀察。對(duì)故障件進(jìn)行分解以查找故障點(diǎn)，容易造成故障點(diǎn)在分解過程中被破壞而無(wú)法定位。

工業(yè) CT 技術(shù)能清晰、直觀、準(zhǔn)確地呈現(xiàn)被檢測(cè)物體內(nèi)部的結(jié)構(gòu)( 包括金屬及非金屬部分的三維信息可視化) 、密度變化以及缺陷的性質(zhì)、位置和大小。在工業(yè)、農(nóng)業(yè)領(lǐng)域有著廣泛的應(yīng)用［3 ～ 7］。工業(yè) CT 的上述特點(diǎn)，使其成為傳感器故障無(wú)損、準(zhǔn)確、高效和全方位檢測(cè)行之有效的手段之一，對(duì)傳感器可靠性的提升具有重要作用。

本文針對(duì)某型航空發(fā)動(dòng)機(jī)數(shù)控系統(tǒng)的高壓壓氣機(jī)進(jìn)口總溫傳感器的故障現(xiàn)象，利用工業(yè) CT 技術(shù)對(duì)其進(jìn)行了無(wú)損檢測(cè)，從而快速、準(zhǔn)確地定位到故障點(diǎn)，并利用其提供的傳感器內(nèi)部信息對(duì)故障原因進(jìn)行了分析，采取了相應(yīng)的改進(jìn)措施。最后通過試驗(yàn)驗(yàn)證了改進(jìn)措施的有效性，結(jié)果表明該傳感器的可靠性得到了顯著提高。

1 、故障描述

某型航空發(fā)動(dòng)機(jī)數(shù)控系統(tǒng)的高壓壓氣機(jī)進(jìn)口總溫傳感器( 以下簡(jiǎn)稱“傳感器”) ，為鎧裝薄膜鉑電阻式溫度傳感器。其核心部件為感溫元件，結(jié)構(gòu)示意圖如圖 1 所示，主要由不銹鋼外殼、薄膜鉑電阻、轉(zhuǎn)接導(dǎo)線、墊塊等組成，其中薄膜鉑電阻的引線與轉(zhuǎn)接導(dǎo)線采用火焰硬釬焊連接。
傳感器的故障為在使用過程中，出現(xiàn)輸出跳變。根據(jù)傳感器的結(jié)構(gòu)特點(diǎn)，可以推斷傳感器內(nèi)部存在接觸不良現(xiàn)象。但受制于前期的故障檢測(cè)手段，始終未能準(zhǔn)確地定位故障點(diǎn)，無(wú)法對(duì)傳感器進(jìn)行結(jié)構(gòu)和工藝上的改進(jìn)，嚴(yán)重影響了傳感器的可靠性提升。


2 、CT 故障定位

2． 1 檢測(cè)設(shè)備與試驗(yàn)條件

傳感器故障件檢測(cè)設(shè)備采用的是通用電氣公司( GE)生產(chǎn)的 X 射線高分辨率微焦點(diǎn)工業(yè) CT 系統(tǒng)。該系統(tǒng)具備180 kV 微焦點(diǎn)定向式 X 射線管，細(xì)節(jié)分辨能力可達(dá) 1 μm;高對(duì)比度的 14 位數(shù)字平板式探測(cè)器，分辨率( 像素大小)200 μm × 200 μm。系統(tǒng)可以獲得各種大小試件的高精度3D 信息。

試驗(yàn)時(shí)，利用微焦點(diǎn)錐束 CT 對(duì)傳感器故障件進(jìn)行檢測(cè)。為獲得高分辨率 CT 圖像，微焦點(diǎn) X 射線源采用了低功率以獲得更小的焦點(diǎn)尺寸，調(diào)節(jié)射線源至故障件的距離以實(shí)現(xiàn)高比例放大成像。故障件斷層掃描間距為 0． 05 mm，通過計(jì)算機(jī)斷層掃描后，利用 CT 數(shù)據(jù)采集和圖像重建軟件得到故障件特定的截面圖像。

2． 2 檢測(cè)結(jié)果與分析

工業(yè) CT 是基于不同密度的物質(zhì)對(duì) X 射線的衰減系數(shù)不同，從而在重構(gòu)圖像中顯示不同的灰度差異，進(jìn)而分辨不同的物質(zhì)。因此，傳感器內(nèi)部的金屬部分( 如鉑電阻引線、導(dǎo)線) 、非金屬部分( 如熱縮套管、膠黏劑) 及空腔能很好的區(qū)分開來。

圖 2 是傳感器故障件的感溫元件部位在某一深度處的CT 縱向二維切片圖像。從圖中可以明顯地看到鉑電阻引線與轉(zhuǎn)接導(dǎo)線的焊點(diǎn)，以及在焊點(diǎn)根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個(gè)斷點(diǎn)。由于未對(duì)故障件進(jìn)行任何破壞性的觀察，因此可以確定該斷點(diǎn)是在工作過程中形成的。并且從圖中可以看出多股轉(zhuǎn)接導(dǎo)線呈松散狀態(tài)。 圖3 是傳感器故障件的感溫元件部位在上述斷點(diǎn)附近的 CT 橫向二維切片圖像。從圖中可以看出轉(zhuǎn)接導(dǎo)線在感溫元件內(nèi)的分布以及其周邊的灌膠狀況。該圖同樣顯示出轉(zhuǎn)接導(dǎo)線比較松散，部分小股線束已經(jīng)斷裂。此外，圖像中明顯有多處面積較大、顏色較深的部分( 例如圖中用白線圈出的區(qū)域) ，說明轉(zhuǎn)接導(dǎo)線周邊的灌膠不充分，有氣泡、空腔存在。
 

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RSI Software Products 9324-RLD2U7PTE RSLOGIX 5000 MINI TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9304-WVPD300DU2R UPGRADE: OUT-SUPT: WINVW 256 TO WINVW PRO DEV 3000

RSI Software Products 9358-PLTM2500U4R UPGRADE: OUT-SUPT: PLANTMETRICS 50 TO 100 WORKCELL

Motion Control 8720SM-063S5QAS4 63 KW/117.5 AMP, 750 VDC, MOTOR W/SNS60,+MPL

A06B-0033-B175#7008 B3/3000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200TBX223 Tool box, 23 point, (IC200UAL006) 24VDC In/Relay Out, requires 120VAC Power, VersaMax SE (IC200SET001) with all software, cables (IC640VPS002)and manuals.

IC698PSA350 RX7i PLC Power Supply, 85 to 264 VAC at 47 to 63 Hz Input, 350 Watt output

MTR-1350-E-D-E-0RR Stepping Motor Nema34 Encoder

ZA06B-0078-B503#0100 B12/3000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD248A3AYNANC0 PowerFlex 700 AC Drive 20B

20G11RD3P4AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-FE PowerFlex 520 Frame E Fan Kit

140XCP40200 Quantum 10槽本版安裝架, 20MM

FRN7.5F1S-4C 12KVA 16.5 A 7.5 KW 3相AC380V/50Hz/60Hz

Z-15GD-B 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1000萬(wàn)次?彈簧式短按鈕型

1492-SPM3C100-N MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40472TB04

模擬量輸出模塊 ES7 232-4HB32-0XB0 SM 1232 AQ 2x14 位

150-SB2NBR SMC-50 SOLID STATE MOTOR CONTROLLER 110A

1734-PDN POINT I/O DeviceNet Interface Module

1783-MCF Stratix 8000 CompactFlash Spare Card

193-ESM-IG-30A-C55 E300/E200 30 Amp Sensing Module

20-750-I1B-C460D430 PowerFlex 750 Replacement Inverter

2090-CPWM7DF-14AF25 MP-Series 25m Length Power Cable

2098-DSD-HV150-DN Ultra 3000 Servo Drive

GA647IFCLNTCDV GCA iFIX iClient Dev

GP-0602NT-F8 GagePort LVDT NT (Full Bridge for Sangamo A6G1, Standard E4-8030)

IC5005CAC0001 PanelClient 15 inch with iFIX Terminal Service License

IC647HSTAE2000KM Alarm and Events Option for Historian - Standard Server 2,000,000 Points (M4 Key)

IC647SPT001 Scheduler Proficy Plant Apps Adapter

IC693MDL733RR 12/24 Vdc Output, 05 Amp, Negative Logic (8 Points)

IC756HDV001K-99 DV Development - HP/UX Op Sys Addt'l User, Korean, Version 9.9

Pico Controllers 1760-L12AWA-NC 12 I/O PICO CONTROLLER, AC

PLC-5/1771 System 1771-IN INPUT MODULE, 24V AC, 8 INPUT

Distributed I/O 1791D-4B0 DNET 24VDC CBLOCK I/O, 4 IN SINK (NOT EXPANDABLE)

Communications 1784-PCM6 1784-PCMK DH+COMMUNICATION CABLE(8 PIN DIN)

Operator Interface 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

Support 9305-RSVADSJPS SUPT RENEWAL CONTRACT FOR 9305RSVADSJP

Support 9515-RSMCLT010S SUPT RENEWAL CONTRACT FOR 9515RSMCLT010EN

EtherNet/IP Products 2711-K10G20 PV1000 GRAYSCALE KEY, ENET & RS232 PRINT

RSI Software Products 9301-2SE340DEU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (DE)

RSI Software Products 9356-PRO2200U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.300 TAG

Motion Control 1326AB-B720E-S2K7L MOTOR,SERVO,460V,30.9NM,3500RPM,SINGL,BRK,IP67

4161-6-5 BCD To 7 SEG Display . 6 Digit, 5VDC. Dust Seal

HMI-CCT-302 BACKLIGHT TUBE 10.5" COLOR TFT QPI3 Series (QPI-3xxxx-Cxx)

IC693CPU313LT 5-Slot Base With Turbo CPU in base (.6 msec), 1K Registers, (12K Bytes User Program) (LT)

SFW-CCSP-6-0.2 CCS for Windows Software Package with Comm Cable & Manual

TRM-21006677 4 point screw terminal motor power connector for IMC servo controller

20BD011A0AYNACD0 PowerFlex 700 AC Drive 20B

20F1ANF212JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-E6P6F104 PowerFlex 40 4 kW (5 Hp) AC Drive

140EHC10500C Quantum 高速計(jì)數(shù)模塊, 35kHz@5 VDC, 5通道,CC

284G-FVD2P3D-N-RG-CBG-DB1-EMI ArmorStart Spare Parts

E2K-X15ME1 15mm,電容式,三線,常開 200mA NPN電源:10-30VDC圓M30

1492-SPM1C400 MCB Supplementary Protector 40 A

通用型變頻器 6SE6 440-2UC13-7AA1 0.37 KW,73 x 173 x 149

電機(jī)啟動(dòng)器 3VU13402MK00

150-C251NBR SMC-3 251A Smart Motor Controller

1609-B1000E 1609-B 1000E

1770-CD9 Data Highway 900-900 ft Length Cable

193-EC1BB E3 3-15 A Overload Relay

194R-TL2 Terminal Lugs, 300Mcm, Kit

2090-CPBM7E7-10AF05 MP-Series 5 m Length Pwr and Brake Cable