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現(xiàn)代航空發(fā)動機(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)動機(jī)性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機(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，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，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，容易造成故障點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，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，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。最后通過試驗驗證了改進(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，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，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工業(yè) CT 系統(tǒng)。該系統(tǒng)具備180 kV 微焦點定向式 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。

試驗時，利用微焦點錐束 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 X 射線源采用了低功率以獲得更小的焦點尺寸，調(diào)節(jié)射線源至故障件的距離以實現(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，以及在焊點根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個斷點。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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通訊處理器CP 6GK7 343-1GX21-0XE0 "CP343-1 IT ， 工 業(yè) 以 太 網(wǎng) 通 訊 處 理 器10/100Mbit/s,RJ45 接口，15 針 D 型接口，IT 功能"

行程開關(guān) 3SE53222SF22

TIA 博途 WinCC 選件 6AV2107-0KR00-0BB0 SIMATIC WinCC WebDiagnostics Server for Runtime Professional

1585J-M8HBJM-3 RJ45 Ethernet Media

1760-IA12XOW6I Pico AC Expansion Input/Output Module

188-K2B250 Miniature Circuit Breaker 25 A

194E-Y80M-1753-6G 80 A 194E Load switch

2090-CHBP8S8-12AA03 Kinetix 6000M IDM Hybrid Cable

2090-UXPC-D0915 MP-Series 15 m Length Interface Cable

BC647MOP001 Logic Developer PC with View for 8000 I/0 Development only with Proficy GlobalCare Complete with USB Hardware key

GC647IFPRSR00075 GCC iFIX Profsnl SCADA 75 I/O Srv

IC200CHS015 I/O interposing spring style

IC646MRA700 View Runtime 700 I/O

IC647IFSTDVUNLMTC iFIX Standard HMI Unlimited Development (M1Component Part)

IC670CBL003 Cable for Connector Style I/O Base (IC670CHS003), 2 Meter, 18 AWG, Con nector on One End

IC697CPX935RR CPU, 96MHz, 12K discrete I/O, 1M byte fixed user memory

IC800SKCEZ100 Encoder cable to connect an S2K to any 30 Watt to 750 Watt S-series servo motor. 10 meters

ControlLogix/1756 System 1756-OF4 ANALOG OUTPUT - CURRENT/VOLTAGE 4 PTS (20 PIN)

Industrial Computers 6182H-10TRH4B VVCE 1000, TOUCH STD, MEM, ENET, AC

Process Control 1757-FIMUPG020 FIELDBUS LICENSE UPGRADE, 20 FIMS

Operator Interface 2711P-RGK4 PROTECTIVE ANTIGLARE OVERLAY, QTY 3

Support 9355-WABITS SUPT RENEWAL CONTRACT FOR 9355WABIT

Support 9354-OD100R 9354-OD100 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 1784-PCICS CONTROLNET PCI BUS SCANNER & MESSAGING CARD WITH

RSI Software Products 9301-2SE2400KOU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9355-WABSNEU1R UPGR: OUT-SUPT: RSLINX SINGLE NODE TO RSLINX OEM

Motion Control MPL-A320P-SK24AA MOTOR,SERVO,2.94 NM,5000RPM,SINGL,230V,BRK,5.1KG

Motion Control 2090-UXBC-D1501 BREAKOUT BOARD CABLE,CN2,ULTRAX000,1M

CBL-12-MP-20 Power Cable, MTR-1216, 1221, or 1231 Stepping Motor, 20 Ft.

IC600KD513RR Amber OptiBasic Operator Interface Terminal, 12" CRT

IC800SGM450M2XE25 4500W, 230V S-Series Servo Motor, 322 in-lb (36.4 Nm), Brake

OC647IFESGRN00300M iFIX Optn: ESig & ERec 300 I/O Runtime (M4 Part)

20AD040A3AYNANC0 PowerFlex 70 AC Drive 40 A at 30 Hp 20A

20DC590N0ENNBNANE PowerFlex 700S AC Drive 590 A 315 kW 20D

20LD360N3ENNAE11WA PowerFlex 700L AC Drive 20L

2707-NC11 MicroView to MicroLogix Comms Cable 1.8M

280-PWRM22E-M1 ArmorConnect 3-PH Power Media drop cable

FX2N-232-BD RS232C 通信用適配器

1492-M6X5H1-100 Connection Products

1494R-N3 Lug Kit

軟啟動器 3RW44476BC45

ET 200SP 6ES5710-8MA11 35mm安裝導(dǎo)軌，長度：483mm

1585D-M4UBDE-1 1585D Ethernet Media Patchcord