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現(xiàn)代航空發(fā)動機正朝著高溫、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，導致傳感器故障發(fā)生，進而干擾控制系統(tǒng)使發(fā)動機性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機安全、可靠工作極為重要。通過對傳感器故障件的科學診斷，探索其失效機理，將有利于傳感器的迭代設(shè)計，進而不斷提升可靠性。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，僅適用于對傳感器的金屬結(jié)構(gòu)進行觀察，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)動機數(shù)控系統(tǒng)的高壓壓氣機進口總溫傳感器的故障現(xiàn)象，利用工業(yè) CT 技術(shù)對其進行了無損檢測，從而快速、準確地定位到故障點，并利用其提供的傳感器內(nèi)部信息對故障原因進行了分析，采取了相應(yīng)的改進措施。最后通過試驗驗證了改進措施的有效性，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)動機數(shù)控系統(tǒng)的高壓壓氣機進口總溫傳感器( 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)接導線、墊塊等組成，其中薄膜鉑電阻的引線與轉(zhuǎn)接導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，始終未能準確地定位故障點，無法對傳感器進行結(jié)構(gòu)和工藝上的改進，嚴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，細節(jié)分辨能力可達 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)接導線的焊點，以及在焊點根部的多股轉(zhuǎn)接導線上出現(xiàn)了一個斷點。由于未對故障件進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)接導線周邊的灌膠不充分，有氣泡、空腔存在。
 

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GP647IFPLDV00150 GCP iFIX Plus SCADA 150 I/O Dev

IC600BF914RR Reed Relay Output Module (6 points)

IC647HSTCR2000KM Collector Redundancy Option for Historian - Standard Server 2,000,000 Points (M4 Key)

IC647TPD915 CIMPLICITY HMI ProServer 1500 I/O Development & Runtime System

IC693PCM311 Prog. Coproc. Mdl., 640 KB (190 KB Basic Prgm), w/Port Exp. Cbl.

IC756MDV000E-99 DV Development - Alpha OpenVMS Op Sys, English, Version 9.9

MicroLogix 1000/1761 System 1761-L32BBB 32 I/O MICROLOGIX 1000

PLC-5/1771 System 1771-IR RTD INPUT MODULE, 3-WIRE RTD'S

Distributed I/O 1792D-4BVT4D 4 SINK/SOURCE INPUTS, 4 SOURCING 0.5 AMP OUTPUTS

Communications 1787-DNPS DEVICENET CLASS II 24VDC POWER SUPPLY

Operator Interface D6190-6.5.18 CONTROLVIEW BATCH MANAGEMENT SW(6190-BAT)MANUAL

Support 9356-STD2100R SUPT REINSTATEMENT CONTRACT FOR 9356STD2100

Support 1789-L30R SUPT REINSTATEMENT CONTRACT FOR 1789L30

EtherNet/IP Products 9351-WKTSRT INTERCHANGE FOR WINDOWS RUNTIME

RSI Software Products 9301-2SE3500JPU2 RSVIEW32 RUNTIME 1500-100K UPGRADE IN-SUPT (JP)

RSI Software Products 9356-PRO2500U9 UPGRADE: IN-SUPT: RSSQL PROF.32000 TO 70000 TAG

Motion Control 0041-5071 N-5600 SHAFT SEAL KIT

44A735709-003 Failure Analysis - PowerMotion

IC200CBL120 CABLE I/O NON-SHIELDED 2 CONNECTORS 2.0M

IC694ALG442 ANALOG COMBINATION MODULE CURRENT VOLTAGE 4 INPUT 2 OUTPUT

MSI-SOL-PROVIDER MSI-SOL-PROVIDER

VSPC32-IMP50 VisualSPC Importer, 50 license pack.

20BD034A0AYYANA0 PowerFlex 700 AC Drive 34 A at 25 Hp 20B

20G11GC2P1JA0NNNNN PowerFlex 755 AC Packaged Drive

22D-B033N104 PowerFlex 40P- 7.5 kW (10 HP) AC Drive

140CRA21110 Quantum DIO站適配器和電源,115/230VAC,獨立,3A

290D-FAP-G1-3 Direct Online Starter

熱電偶/PT100輸入，繼電器輸出，3個報警

1492-SPM2B250 MCB Supplementary Protector 25 A

軟啟動器 3RW30162BB04

電機啟動器 3VU16401MQ00

150-F108NBRB SMC Flex Smart Motor Controller

1732D-16CFG1212W Armor WeldBlock 16 Point Block

1771-NT2 1771 Analog Module

193-EC5PB E3 Plus 0.4-2 A Overload Relay

198E-DF14168 Ip66/Nema 4/4X/12 Metal Hinged Enclosure

2090-CPWM6DF-16AA03 TL-Series 3m Standard Power Cable

2094-EN02D-M01-S1 Kinetix 6200/6500 Control Module

DNR240PS24-I FIELD PSU 24VDC 10A

GFK-0870 Host Communications Toolkit for C/C++ Applications User's Manual

IC210EMS001 Modbus RTU slave communications expansion module, 24V DC power source

IC647AUR025 PA Universal Reporting Client 25 pak