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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(guò)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(guò)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(guò)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(guò)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(guò)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(kāi)來(lái)。

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(guò)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(shuō)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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Motion Control 1326AB-B515G-M2K5L MOTOR,SERVO,460V,10.4NM,5000RPM,MULTI,BRK,IP67

4161-3-24-.8-N4 BCD To 7 SEG Display . 3 Digit, (.8") 24VDC. NEMA 4

HMI-CAB-C108 CABLE OMRON C200H

IC693CBL307 Cable, Extension, 2 Meters (Use with MDL652-653, MDL750-751)

QPM3D200B2P 6" Blue Monochrome Mini, TCP Label, 24Vdc

TGT-S000-1-1RR Target System Module with 2 MB RAM

20BC8P7A0AYNANA0 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF034AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E012H204 PowerFlex 40 7.5 kW (10 Hp) AC Drive

140AVI03000 Quantum 模擬量輸入, 8通道, 雙極性, 多量程

284E-FVD6P0Z-25-RR-3-DB1-EMI EtherNet Variable Frequency Drive

E2E-X14MD1 14mm,電感式，兩線，常開(kāi) 100 mA 電源：12-24VDC圓M18

1492-SPM1C080-N MCB Supplementary Protector 8 A

通用型變頻器 6SE6 420-2UD31-1CA1 "11 KW，185 x 245 x 195"

電機(jī)啟動(dòng)器 3VU13401MK00

150-C135NBD SMC-3 135A.. Smart Motor Controller

1608P-050A380V4S 50 A Pro DySC Sag Corrector

1769-RL2 CompactLogix Replacement Part

191E-AND3-CB25C-R 1.6-2.5 A Economy Rev Starter W/Ckt-Bkr

194R-R11 194R Standard Operating Shaft

2090-CPBM7DF-16AF60 MP-Series 60 m Length Cable

2090-XXTPMP-16S03 MP-Series 3 m Length Power Cable

CP2I-0WPB-0140-AZ Power cable with straight connector for A2HVis, A4HVis, B2HVis and B4HVis motors. 14 meters

GF-6012R Connecting FlashCable to Surtronic 3+.

IC200UEI016 VersaMax Micro Expansion 16 point Input (16) 24VDC In, 24VDC Power Supply (includes IC200CBL501).

IC647ABK001 PA Spare Key

IC647PATYOKG Proficy PAT - Driver For Yokogawa

IC693CBK003 Cable Kit for High Density I/O Modules (includes CBL331 and CBL332)

IC754ACC06BEZ01 SS-Bezel for 6 Inch Mono & TFT QP-V & C

IMC-313D-X-DRR IMC-D Series Servo Motor Controller, DeviceNet, 3 Amp

SLC/1746 System 1747-PSD PROGRAM STORAGE DEVICE-SLC 5/03 THRU 5/05

Open Automation Systems 1784-PM02AETP01 1784PM02AE TERMPANEL WITH 1 METER CABLE

Application-specific products 1404-M605B-CNT 1404-M6 CONTROLNET PM3000 24V P.S.

Operator Interface 2711-K10G10 PV1000 GRAYSCALE KEY, DNET & RS232 PRINT

Support 9301-2SE3300DES SUPT RENEWAL CONTRACT FOR 93012SE3300DE

Support 9380-RSBVBR SUPT REINSTATEMENT CONTRACT FOR 9380RSBVB

DeviceNet Products 1792D-CB12 MAXUM MEDIA BASE W/12MM CONNECTORS

RSI Software Products 9301-2SE3300DEU2 RSVIEW32 RUNTIME 150-1500 UPGRADE IN-SUPT (DE)

RSI Software Products 9358-EP03ENE RSBIZWARE EPROCEDURE 03 UNITS

Motion Control MPL-B4530K-RK24AA MOTOR,SERVO,8.36 NM,4000RPM,RSLVR,460V,BRK

Motion Control 2090-XB33-16 RESISTIVE BRAKE MODULE, 33A, 16 OHM

GQPH-DEM-S02 QUICKPANEL 6" HAND HELD STN GE LABEL

IC646MRA000 View Runtime 8,000 I/O

MTR-1N31-I-E-A-S-0 Stepping Motor Nema34, Parallel Wdg, Encoder, Parallel Wdg

QPLCTAE0000 12.1 inch Color TFT/ TCP/ Ethernet/ CF Card/ 110VAC

20BC043A3AYNACC1 PowerFlex 700 AC Drive 43 A at 22 kW 20B

20F11ND014AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RF018-CS PowerFlex EMC Filter

2711P-RL7C PanelView Plus Accessory

280S-PWRM35A-M8 ArmorStart Three-Phase Power Media

C200H-ID001 輸入單元, 8點(diǎn), 無(wú)電壓接NPN

1492-PDL31S1 175 A Power Distribution Block

通訊處理器 6ES7440-1CS00-0YE0 CP440，PtP-串行通訊，1 個(gè)通道，RS422/485，

變送器 3RS10201DD00

1497-B-BASX-1-N Control Circuit Transber

1585J-M8UBJM-50 RJ45 Ethernet Media

1761-L32BBB MicroLogix 1000 32 Point Controller

188-K3C040 Miniature Circuit Breaker 4 A

194L-E32-1751 32 A 194L Load Switch

2090-CPBM6DF-16AA30 TL-Series 30m Power and Brake Cable

2090-XXNFMP-S90 MP-Series 90 m Length Feedback Cable

BC647PSC000 Proficy Process Systems 5000+ I/O with CIMPLICITY with Global Care

GC647PCM003 GlobalCare Complete for Proficy Change Management Server - 3 Concurrent Users

IC200MDL240LT INPUT 120VAC (2 GROUPS OF 8) 16PT (LT)

IC646NTS010 Terminal Services - 10 Pack License

IC647MGP001 Plant Applications Maintenance Gateway Adapter

IC676CBLPBB020 IP67 Profibus Cordset - 2 Meters