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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(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(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。

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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IC647BSU255 Batch Server Pak Upgrade (20 to 255 Units)

IC647PRTHE100C Proficy Portal Historian Edition Client Pack 100 Users (M1 Key)

IC693CPU367 CPU 367Module (240K Bytes configurable Supports Profibus DP Slave (Version 1 supported). One Profibus port and one RS-232 service port.

IC756ADV000K-98 DV Development - AIX Op Sys, Korean, Version 9.8

MSI-EFF-50-43 Efficiency Mang Clients 50 Pack-43

SLC/1746 System 1746-RT26 REPLACEMENT TERMINAL BLOCK - ANALOG OUTPUT

Distributed I/O 1738-IB8M12 24VDC 8 SINKING INPUTS WITH M12 CONNECTORS

Application-specific products D6300-6.9.1 REMOTE I/O MONITOR SW(6300,6310-MS)REFERENCE GUIDE

Operator Interface 2711-NL3 BACKLIGHT PV600 KEY & KEY&TOUCH SER B & EARLIER

Support 9302-REPR SUPT REINSTATEMENT CONTRACT FOR 9302REP

Support 9510-PPKEWENS SUPT RENEWAL CONTRACT FOR 9510PPKEWEN

DeviceNet Products 1788-DNBO DEVICENET LOGIX DAUGHTERCARD - OPEN CONNECTOR

RSI Software Products 9301-2SE3353DEE RSVIEW32 RUNTIME 5K WITH RSLINX (GERMAN)

RSI Software Products 9326-AD1USENE RSAUTOMATION DESKTOP 1 USER W/ SQL SERVER

Motion Control MPG-A004-091S24 MOTOR,SERVO,GEAR RATIO 91,15NM,66RPM,SINGL,BRK

HE693ISOBLK DIN rail mounted cold junction compensation block for thermocouple b modules.

IC655MDL533RR 5/12 VDC (TTL) Input (64 points)

QPI3D200C2P QUICKPANEL COLOR 10.5" TFT

ST-5101 STXi High Speed Counter module, 1 Channel, 5VDC 1.5MHz

20BC170A3ANNANC0 PowerFlex 700 AC Drive 20B

20F1AGC456JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A012N104 PowerFlex 40- 2.2 kW (3 HP) AC Drive

140DAI75300 Quantum 開關(guān)量AC輸入,32點(diǎn),230VAC,8點(diǎn)成組隔離

284D-FVD2P3Z-10-CR DeviceNet Variable Frequency Drive

E3JK-T31 5m,分離式,明通，PNP晶體管輸出100mA，電源:10-30VDC

1492-SJ5B-10 IEC Term Blck 10 pole Side Jumper

人機(jī)界面 6ES7862-0AC01-0YA0 S7 軟件冗余 V1.2

6ES78221AA030XE5

1497B-A12-M14-0-N Control Power Transber

1606-XLS240E-D XLS 10 Amp Power Supply

1769-CLL3 CMPLX 1 m Left to Left Bus Exp Cable

188-K4D200 Miniature Circuit Breaker 20 A

194R-D160-1753 Disconnect, Fused, Din-Type, 160 A

2090-CPBM7DF-12AA03 MP-Series 3m Power and Brake Cable

2090-XXNPMP-16S01 MP-Series 1 m Length Power Cable

CBL-14-MP-30 Power cable for MTR-1235 or MTR-1300 or MTR-1400 series splashproof stepping motors. 30 feet

GF-0193 Connecting FlashCable to Federal Maxum Plus E2.

IC200TBX040 Tool box, Micro 40 and software. Includes (IC200UDD040) 24VDC In/24VDC Out, requires 24VDC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with Proficy software, manuals and cables (IC646MPM101)

IC646TBPAS500 Production Accounting Server 500 mass balance streams

IC647NPG000 CIMPLICITY Alarm Cast Standard (replaces CIMPLICITY Pager in version 8.2) Will enable CIMPLICITY PAger in version 8.1 and earlier.

IC693ACC316 Connector Kit, 24 Pin, Qty (10), Solder Eyelet (For MDL654, 655, 752, 753)

IC752BCL000 DataPanel Download Cable

IC800VMCE1030 Encoder cable for 1 kW to 3 kW VersaMotion servo motors- 3 meter

SLC/1746 System 1746-OBP16 HIGH CURRENT DC OUTPUT MODULE

Industrial Computers 6189-COMMCARD 2 CHANNEL RS232 PCI CARD

Application-specific products 6556-SPAKK PROGRAMMABLE LIMIT SWITCH & DIE MONITOR START. KIT

Operator Interface 2711-B6C15 PV600 COLOR KEY&TOUCH, CNET & RS232 PRINT

Support 9301-2SE2300PTS SUPT RENEWAL CONTRACT FOR 93012SE2300PT