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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發(fā)動(dòng)機(jī)安全、可靠工作極為重要。通過對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)的傳感器故障檢測方法存在下列局限性: 1) 無損檢測時(shí)，一般采用 X 射線機(jī)，僅適用于對傳感器的金屬結(jié)構(gòu)進(jìn)行觀察，非金屬部分無法清晰顯現(xiàn)。且一般只能二維成像，無法三維立體顯示。2)破壞性觀察。對故障件進(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損、準(zhǔn)確、高效和全方位檢測行之有效的手段之一，對傳感器可靠性的提升具有重要作用。

本文針對某型航空發(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)對其進(jìn)行了無損檢測，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手段，始終未能準(zhǔn)確地定位故障點(diǎn)，無法對傳感器進(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 檢測設(shè)備與試驗(yàn)條件

傳感器故障件檢測設(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;高對比度的 14 位數(shù)字平板式探測器，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 對傳感器故障件進(jìn)行檢測。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 檢測結(jié)果與分析

工業(yè) CT 是基于不同密度的物質(zhì)對 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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194E-CA80E-TN-PE 194E Load switch

2090-CCMUSDS-48AA01 Kinetix 3 cable to 1203-USB 1m

2090-DANPT-16S12 TL-Series 12 m Length Power Cable

ABKSTDN0000/ABR 6 inch Color STN/ TCP Label/ 24VDC/ with AB Remote I/O/ UL/ cUL/ CE/ UL1604

GC646PDS100E Proficy GC for OP CAD Designer EWS Software

HE800ACC106 Cage-clamp (screw) style I/O plug, 6-terminal. (Qty 10)

IC640BLD304RR Series Six Terminator Board

IC647HSTSSEO1250KM eSignature Option for Historian - Standard Server 1,250,000 Points (M4 Key)

IC660BLD110 Cover w/Label for IC660BBD110

IC695CHS016CA RX3i 16 universal slots backplane with conbal coating.

IC756WET100J-23 Custom Editor Toolkit, Japanese, Version 2.3

CompactLogix System 1769-PB4 24VDC INPUT P0WER SUPPLY: 4A @ 5VDC 2A @ 24VDC

PLC-5/1771 System D1771-6.5.113 BASIC MODULE USER MANUAL

Process Control 1757-FFLD2 2 H1 / HSE FOUNDATION FIELDBUS LINKING DEVICE

Operator Interface 2711P-B7C4B2 PV PLUS 700, KEY/TOUCH, ENET, AC PS, EXT MEM

Support 6500-PS2R SUPT REINSTATEMENT CONTRACT FOR 6500PS2

Support 9358-PLTM2500S SUPT RENEWAL CONTRACT FOR 9358PLTM2500ENE

Support F1785-BCMSERC FIRMWARE UPGRADE FOR 1785-BCM COMMUNICATION MODULE

RSI Software Products 9301-2SE2200KOE RSVIEW32 WORKS 300 (KOREAN)

RSI Software Products 9701-VWSB000FRU1 RSV SE STATION 25 - UNLTD DISP UPGRADE (FRENCH)

RSI Software Products 9399-COMPAREUG RSCOMPARE USERS GUIDE

Motion Control 2098-IPD-HV050 HIGH VOLTAGE DRIVE, 11A/22A, ULTRA5000

AD693SLP300 90-30 State Logic Processor Module (SLP), (46 Kbytes), w/Manual.

IC300ADC920 12 channel Analog Inputs Current, Voltage or Thermistor. Channel selectable. 0-20ma, 0-5VDC, Thermistor (-37 to 115 C/ -35 to 240F), 12 bit Resolution

IC752DSX003RR Datapanel 160 with Advanced Software (Real time trends and Host communications)

MTR-3S35-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6079-H401 Dynamic braking module required for Alpha SVM1-180HVi amplifier

20BE125A0ANNAND0 PowerFlex 700 AC Drive 20B

20G14TC540AN0NNNNN PowerFlex 755 AC Packaged Drive

25-RF029-EL PowerFlex 520 29.2A 600V EMC Filter Kit

2711P-RW3 PanelView Plus Accessory

FRN 1 5 P11S-4CX 2 3 KVA 30A 15 KW 3相AC380V/50Hz/60Hz

1492-JD3-W 2.5 mm Double Level Terminal Block

1492-W3 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40752BB44

工藝型 CPU 6ES7 511-1UK01-0AB0 CPU 1515TF-2 PN，750 KB 程序，3 MB 數(shù)據(jù)；30 ns；集成 X1: 2x PN 接口，支持 IRT；X2: 1x PN 接口，支持 RT

156-B20AB1 20 A Single Phase Solid State Contactor

1746-F3 SLC Power Supply Fuse

1786-FS60 ControlNet Fiber Optic Cable

193-T1AB32 2.3-3.2 A IEC Bibllic Overload Relay

20-FR09104 PowerFlex 700H/S Cover Kit

2090-CSBM1DF-14AA04 Kinetix Cable Single DSL 2090-Series

20AC015A0AYNADC0 PowerFlex 70 AC Drive 20A

GA647TDV935 Proficy GlobalCare Assist for CIMPLICITY HMI Server 35,000 I/O Development and Runtime System

GP647IFPRRN00075 GCP iFIX Profsnl SCADA 75 I/O Run

IC600CB500RR Arithmetic Control Module - ALU2

IC647HSTCS150KM Historian Enterprise Corporate Server 150000 Points (M4 Key)

IC647TRT915 CIMPLICITY HMI Server 1500 I/O Runtime System

IC693PWR322LT Power Supply, 24/48 Vdc, Standard (LT)

IC756MDV010J-97 DV Draw Dvlpnt on Alpha OpenVMS, Japanese, Version 9.7

MicroLogix 1000/1761 System 9399-RL50GRIT RSLOGIX 500 GETTING RESULTS GUIDE (ITALIAN)

PLC-5/1771 System 1771-NOC HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1794-ACN15 SINGLE MEDIA ADAPTER FOR CONTROLNET

Communications 9351-WESRT INTERCHANGE FOR WINDOWS RUNTIME

Operator Interface D6190-6.5.32 CONTROLVIEW TEXAS INST. USERS MANUAL

Support 9358-BA03S SUPT RENEWAL CONTRACT FOR 9358BANT03ENE

Support 9392-CDRSR SUBSCRIPTION RENEWAL FOR DATADISC CD

RSI Software Products 9324-RL0100FRE RSLOGIX 500 STARTER FRENCH CD

RSI Software Products 9301-2SE3500U2R UPGRADE: OUT-SUPT: RSVIEW32 RUNTIME 1500 TO 100K

RSI Software Products 9356-STD2300U1R UPGRADE: OUT-SUPT: RSSQL STAND.150 TAG TO 1500 TAG