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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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Motion Control MPL-A4540F-SK22AA MOTOR,SERVO,10.2 NM,3000RPM,SINGL,230V,9.5KG

Motion Control 2090-XXNPMP-14S03 CABLE,NON-FLEX,MOTOR POWER,MP/1326AB,14 GAUGE,3M

GABK2D100S2P/AD QUICKPANEL 6" STN W/AB DH+ GE LABEL

IC641SWC701 Logicmaster 90-70 S/W Dev. Pkg., 3.5"/5.25" disks + CD-ROM docs.

IC800SSI107RP2 7.2A, 115/230V, Profibus S2K Servo Controller for MTR Series Motors

PSPC-ADMIN100 Prof Shop Floor SPC Admin 100 User

20BB070A0ANNANC0 PowerFlex 700 AC Drive 70 A 25 Hp 20B

20DF1K1A0ENNBNANE PowerFlex 700S AC Drive 20D

2198-CAPMOD-1300 Kinetix 5500 Capacitor Module

2711P-K4C20A8 PanelView Plus 6 Graphic Terminal

280-PWRM35D-M25 ArmorConnect 3-PH Power Media trnk cable

CPM2AH-30CDR-A NEW 30點(diǎn)主機(jī) AC100-220V 18點(diǎn)入12點(diǎn)繼電器輸出 自帶RS232C口 中國(guó)產(chǎn)

1492-MS6X12H21-30 Connection Products

0.05| s，PROFIBUS-DP 主/從接口,PROFINET 接口

行程開關(guān) 3SE53121SD11

運(yùn)行版軟件 6AV2105-2FH04-0BD0 SIMATIC WinCC Runtime 專業(yè)版 Powerpack 2048 PowerTags -> 4096 PowerTags V14

1585J-M4UBJM-50 RJ45 Ethernet Media

1756-PA75K ControlLogix AC Power Supply

188-K1C320-N Miniature Circuit Breaker 32 A

194E-KA63E-P11 194E Load switch

2090-CFBM7DF-CEAF07 Kinetix 7m Flexible Cable

2090-UXNBMP-18S60 MP-Series 60 m Length Brake Cable

BC646SPY365 Solution Provider Annual Base Lic.-Europe

GC647IFESGDV00075 GCC iFIX Optn: ESig & ERec 75 I/O Dev

IC200ALG430LT ANALOG MIXED 12 BIT INPUT CURRENT 4CH AND OUTPUT CURRENT 2CH (LT)

IC646MCD001 Proficy Machine Edition 5.70 CD Set - Includes Installation CD and Supplemental CD with NO License

IC647IFPRRN00150C iFIX Profsnl SCADA 150 I/O Runtime (M1Component Part)

IC660TBA023 Terminal Assembly for IC660BBA023

IC697CHS782 Integrators Rack, 17 Slots, Rear Mount

IC800CBL067 Power cable for B0.5/3000 motor. 14 meters

ControlLogix/1756 System 1756-A17 17 SLOT CONTROLLOGIX CHASSIS

Industrial Computers 6182H-7KRH6D VVCE 700, KEYPAD, STD MEM, RIO/DH, DC

Process Control 9358-PBBK60ENE RSBIZWARE BATCH FOR PLX BACK-UP KEY 60 UNITS

Operator Interface 2711P-T15C4D1 PV PLUS 1500, TOUCH, ENET, DC PS, STD MEM

Support 9352-WGG200S SUPT RENEWAL CONTRACT FOR 9352WGG200

Support 9330-GC100S SUPT RENEWAL CONTRACT FOR 9330GC100

ControlNet Products 1786-RPA CONTROLNET MODULAR REPEATER ADAPTER

RSI Software Products 9301-2SE235FRU1R RSVIEW32 WORKS 150-5K UPGRADE OUT-SUPT (FR)

RSI Software Products 9355-JBOXENE RSJUNCTIONBOX

Motion Control MPL-A310F-HK22AA MOTOR,SERVO,1.58NM,3000RPM,ENCDR,230V,3.0KG

Motion Control 2090-UXNBMP-18S15 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 15 MTR.

CBL-30-BT-20 Brake Cable, MTR-3S & MTR-3T Series Servo Motors with Brake, 20 Ft.

IC641VPS999 VersaPro Standard Edition Unlimited Seat Site License - Windows Programming Software for Series 90-30 and VersaMax PLCs

QPK2D101S2P QUICKPANEL 6" STN COLOR WITH CE MARK