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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(xiàn)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(chēng)“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(xiàn)、墊塊等組成，其中薄膜鉑電阻的引線(xiàn)與轉(zhuǎn)接導(dǎo)線(xiàn)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(xiàn)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(xiàn)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(xiàn)源采用了低功率以獲得更小的焦點(diǎn)尺寸，調(diào)節(jié)射線(xiàn)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(xiàn)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(xiàn)、導(dǎo)線(xiàn)) 、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(xiàn)與轉(zhuǎn)接導(dǎo)線(xiàn)的焊點(diǎn)，以及在焊點(diǎn)根部的多股轉(zhuǎn)接導(dǎo)線(xiàn)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(xiàn)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(xiàn)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(xiàn)比較松散，部分小股線(xiàn)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(xiàn)圈出的區(qū)域) ，說(shuō)明轉(zhuǎn)接導(dǎo)線(xiàn)周邊的灌膠不充分，有氣泡、空腔存在。
 

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通用型變頻器 6SE6 440-2UC22-2BA1 "2.2 KW,149 x 202 x 172"

電機(jī)啟動(dòng)器 3VU13402NH00

150-C25NBR SMC-3 25A Smart Motor Controller

1609-D1000E Uniterruptible Power Supply

1770-XG Dropline Connector Kit

193-EC1DE E3 9-45 A Overload Relay

195-GA02 Auxiliary Contact

2090-CPBM7E7-10AF25 MP-Series 25 m Length Cable

2093-AMP5 Kinetix 2000 Axis Module

CP8B-1WEB-0140-AZ Shielded motor power cable for B0.4is/B0.5is/B1is motors (elbow connector). 14 meters

GF-AU5V/AMS Connecting FlashCable to

IC200UEX164 VersaMax Micro 64 point expansion (40) 24VDC bs, relay outputs, AC power supply. Compatible with Micro 20/40/64 revision -Bx hardware only version 4.0 firmware and above.

IC647AEC050 PA Efficiency Client 50 Pak

IC647PCMS03 Proficy Change Management Electronic Signature Option - 3 Concurrent Users

IC693CBL334 Cable, Right Side, Two - 24 Pin 90 Degree Connectors, .5 Meter

IC754CBL06MTD Ctrl Loaded 6 In Mono Touch DC Blank

IMC-78005773 Custom modified IMC enhanced stepping motor controller

SLC/1746 System D1746-6.16DE SLC500 THERMOC'PL/MV ISOL.INPUT MOD. USR MNL(GERMA

Distributed I/O 1732D-OB8EM8 DEVICENET 24VDC 8 0.5A OUTPUT W/M8

Application-specific products 1404-M805B-CNT-02 1404-M8 CONTROLNET PM3000 CLASS 0.2 24V P.S.

Operator Interface 2711-T10C12 PV1000 COLOR TOUCH, PBUS & RS232 PRINT

Support 9301-2SE3400FRS SUPT RENEWAL CONTRACT FOR 93012SE3400FR

Support 9381-PA10KENR SUPT REINSTATEMENT CONTRACT FOR 9381PA10KEN

DeviceNet Products 1790-T0W8X LDX I/O, 24VDC, 8 RELAY OUT EXPANSION, TERM BLK

RSI Software Products 9301-2SE3300U2R RSVIEW RUNTIME 150 TO 1500 UPGRADE: OUT-OF-SUPPORT

RSI Software Products 9358-PB10ENE RSBIZWARE BATCH FOR PROCESSLOGIX 10 UNITS

Motion Control MPL-B520K-SJ24AA MOTOR,SERVO,10.7 NM,4000RPM,SINGL,460V,BRK,13.9KG

Motion Control 9101-1478 MATING CONNECTOR KIT/J3 26 PIN MINI D(SOLDER CUP)

GQPK2D100S2P QUICKPANEL COLOR 6" STN GE LABEL

IC646MRD300 Logic PC (HRT) 300 Tag Runtime System

MTR-3T24-H-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SNAP 5C5 PC Port is 9-pin male and port on CNC is 25-pin male. This is for Xon/ Xoff communications.

20BC072A0AYNACC0 PowerFlex 700 AC Drive 72 A 37 kW 20B

20F11NE2P7AA0NNNNN PowerFlex 753 AC Packaged Drive

22148-222-01-R SOCKET CONNECTOR

140CPU53414BC Quantum Quantum 534 PLC CONTROLLER CC

281D-F23Z-25D-CR ArmorStart Direct Online RVSG Starter

C200H-OD501 多點(diǎn)I/O單元, TTL輸出 5VDC 35mA 32點(diǎn)

1492-RAIFM4-3 Connection Products

存儲(chǔ)卡 6ES7952-1AH00-0AA0 RAM/256K

變送器 3RS11011CK30

1497-E-M4-3-N Control Circuit Transber

1606-XL480F-3H Power Supply XL 480 W Power Supply

1762-L40AWAR MicroLogix 1200 40 Point Controller

188-K3C630-N Miniature Circuit Breaker 63 A

194L-HC4A-175I Type A Size 4 Switch Actuator

2090-CPBM7DF-06AA03 MP-Series 3m Power and Brake Cable

2090-XXNPMF-10S05 Kinetix Drives 5m Standard Cable

BC647SPX365 "Solution Provider 1st Year Subbion includes 2 physcial M4 keys, Gl obal Care Complete (iGC SP1)

GC647PRTEE010 GlobalCare Complete - Proficy Portal Enterprise Edition Client Pack 10 Users Ver 3.0

IC200MDL650 Input 24VDC POS/NEG logic (4 groups of 8) 32 points

IC646PCMS1C Proficy Change Management Electronic Signature Module 100 Pack

IC647MPS050 Logic Developer PLC Standard 50 Pack with USB Hardware key

IC676PBM442 IP67 Mixed Block - 24 VDC Positive Logic - 4 In/4 Out 2A - Profibus

IC697PWR720RR Replacement Power Supply Adaptor

IC800SSI107S1 7.2 amp 115/230 VAC S2K servo controller for S-series motors

SLC/1746 System 1747-L30B 30 I/O FIXED HARDWARE STYLE

Industrial Computers 6189-RPRH VVCE LOGIC MODULE, 128MB FLASH, 128MB RAM

Process Control D1770-6.5.21 SMART TRANSMITTER TOOLKIT USER MANUAL

Operator Interface 2711-B5A3L2 PV550 MONO KEY&TOUCH, DH485 & RS232 PRINT

Support 9303-3CS0E20UR UPGRADE: OUT-SUPT: DRIVEMONITOR TO DRIVEMONITOR32

Support 9371-RSWDI1S SUPT RENEWAL CONTRACT FOR 9371RSWDI1

ControlNet Products 2706-P92C INVIEW MESSAGE DISPLAYS

RSI Software Products 9301-2SE2500ITU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9358-BBKEY30ENE RSBIZWARE BATCH BACK-UP KEY 30 UNITS

Motion Control MPL-A4530K-MJ22AA MOTOR,SERVO,8.36 NM,4000RPM,MULTI,230V,8.2KG

Motion Control 2090-UXPC-D0915 CABLE,9/9 POS,45 DEG D/STRAIGHT D,15M

CBL-6113 Cable. IBM COMP. To Model 9650, 25 Pin PC COMM. Port

IC641LCN053 Runtime license for DEC VAX/VMS

IC800SLMCONKITVB Connector Kit, 1 kW to 2.5 kW S-Series Servo Motors with Brake