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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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IC695PBM300 RX3i PROFIBUS Master Module (must be installed on RX3i PCI bus). The module supports PROFIBUS V1 Master functionality. The PROFIBUS Master module requires an RX3i CPU with firmware version 2.9 or later

MTR-1220-0-D-E-0RR Stepping Motor Nema23 Double Shaft

VSPCSE-SF10 VisualSPC SE ShopFloor includes Attribute Data Collection, Measurement Systems Analysis and A-681 interface cable. 10 license pack.

20BD077A0ANNANB0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11LF960JN0NNNNN PowerFlex 755 AC Packaged Drive

22F-A4P2N113 PowerFlex 4M- 0.75 kW (1 HP) AC Drive

490NAA27104 Quantum MODBUS PLUS電纜,1500'

291E-FBP-G1 Direct Online Reversing Starte

PYF14A-E 導(dǎo)軌安裝型：MY4J，MY4NJ

1492-SPM2D200 MCB Supplementary Protector 20 A

軟啟動(dòng)器 3RW30471BB14

電機(jī)啟動(dòng)器 3VU16401CL00

150-F361FBD Encl. SMC Flex Smart Motor Controller

1732E-IR4IM12R ARMORBLOCK 4 POINT RTD INPUT

1771-WB 12 Point Terminal Field Wiring Arm

193-EEKZ E1 Plus 60-300 A Overload Relay

20-750-2263C-1R2T PowerFlex 750 24V Tran IO Option module

2090-CPWM7DF-10AA03 MP-Series 3m Servo Power Cable

2097-V32PR0 Kinetix 300 Servo Drive

ENSP1F5 Bulkhead Passthrough Connector, Female/Female

GFK-1885 ViewStation CE II ControlStation CE II Hardware User's Guide

IC220EBI002 VersaPoint Ethernet Standard Network Interface Unit. Supports Modbus TCP network communications. Requires (1) IC220TBK087.

IC647CSPR010 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 10X monitored KPIs

IC647PSF000 Proficy Process Systems 5000+ I/O with iFIX

IC693MDL231 240 Vac Isolated Input (8 Points)

IC756CDV000E-98 DV Development - Compaq True64 Op Sys, English, Version 9.8

MSI-MGMT-43 Production Mang Clients-43

PLC-5/1771 System 1785-L30B PLC-5/30 CONTROLLER, 32K WORD SRAM

Distributed I/O 1738-SSIM23 SSI ABSOLUTE ENCODER INTERFACE

Communications 1787-PLUG10R DEVICENET 10 POSITION CONNECTOR WITH JACK SCREWS

Operator Interface 2711-NM14 4 MBYTE PC FLASH MEMORY CARD FOR PANELVIEW E TERMS

Support 9304-WVD128R SUPT REINSTATEMENT CONTRACT FOR 9304WVD128

Support 9324-RLD250DEE RSLOGIX 5000 LITE EDITION GERMAN

DeviceNet Products 2711-B5A10L2 PV550 MONO KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335KOU1R RSVIEW32 RUNTIME 150-5K UPGRADE OUT-SUPT (KO)

RSI Software Products 9371-EDESI1U4 UPGRADE: IN-SUPT: RSWIRE DET IEC STD TO DES IEC

Motion Control MPG-B010-091S22 MOTOR,SERVO,GEAR RATIO 91,35NM,71RPM,SINGL,460V

Silver Series 2711-K14C8 PV1400 COLOR KEY, DH+ & RS232 PRINT

HE693STG884 8-ch. +/-25mV, +/-50mV, +/-100mV with 16-bit resolution + weighing func.

IC670CHS004 TC Cold Junction Compensation Base

QPI-PBS-201 MODULE PROFIBUS DP SLAVE W/O MEMORY RETENTION

ST-7118 STXi Potential Distribution module module, 24VDC, 8 points, 10A

20BC260A3AYNACC0 PowerFlex 700 AC Drive 20B

20F1ANC260JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-B024N104 PowerFlex 40- 5.5 kW (7.5 HP) AC Drive

140DAO84010 Quantum 開(kāi)關(guān)量AC輸出,16點(diǎn),24-115VAC,隔離,4A/點(diǎn)

284D-FVD6P0D-25-CR-EMI DeviceNet Variable Frequency Drive

E3F3-T31 5m 對(duì)射式，明通，PNP晶體管輸出100 mA，電源：10-30VDC 直徑18mm

1492-SPM1B040 MCB Supplementary Protector 4 A

6ED1052-1FB00-0BA5 "LOGO!230RC 8DI/4DO,230V,10A 繼電器輸出"

6ES73317PF114AB2

1497B-A9-M14-0-N 500VA 240x480-120x240V 60Hz CPT

1606-XLS960F-3 380 to 480VAC In 48 to 54VDC Out 960W PS

1769-IQ6XOW4 CMPLX 10 Pt 24VDC D/I Relay D/O Module

190-HM4 Circuit-Breaker Accessory

194R-J30-1753 194R Disconnect Switch

2090-CPBM7DF-14AA30 MP-Series 30m Standard Cable

2090-XXNPMP-8S30 MP-Series 30 m Length Power Cable

CBL-3C-RD-10 Resolver cable for MTR-3S or MTR-3N series servo motors. 10 feet

GF-0800-1 Connecting FlashCable to Generic Torque (bare-ended cable).

IC200TBX540 Tool box, Micro 40, QuickPanel color touch screen and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200UEM001) Ethernet option board, QuickPanel Display (IC754VSI06STD) with Proficy software, manuals and cables (

IC646TBSPMSW001 Smart Process Monitoring SPC+ Web Client

IC647NTS050 CIMPLICITY HMI Terminal Services 50 User Pack

IC693ALG220LT Analog Input, Voltage/Current, 4 Channels (LT)

IC752CGE101 SNP 485 cable for DataPanel 30/50

IC800VMM02LBKSE25 200 W VersaMotion servo motor with 24 VDC holding brake (0.64 Nm)

SLC/1746 System 1746-NO8V 8 CHANNEL ANALOG VOLTAGE OUTPUT FOR SLC 500

Industrial Computers 6189V-DIMM512 DIMM MEMORY 512MB

Application-specific products 1403-DMB DISPLAY UNIT FOR POWERMONITOR

Operator Interface 2711-K6C15 PV600 COLOR KEY, CNET & RS232 PRINT

Support 9301-2SE2500DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2500DE

Support 9323-P1003ENS SUPT RENEWAL CONTRACT FOR 9323P1003EN

DeviceNet Products 1734-OW4 24V DC COIL N.O. DPST 4 RELAY MODULE