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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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RSI Software Products 9323-1003ENE RSTUNE

Motion Control MPL-A420P-MK22AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,230V,5.0KG

Motion Control 2090-UXNFBN-K15 CABLE,ULTRA, NON-FLEX,SKWD,R/A,15M

CBL-13-MP-10 Power Cable, MTR-1235, 13xx, 14xx & 1N Series Stepping Motors, 10 Ft.

IC600YR554RR 13" I/O Rack with High Capacity P/S, 24Vdc (8 Slots)

IC800SKCS030 Cable, PC to S2K Controller Serial Communications, 3 Meters

OC647IFGLBLCLN001M-51 iFIX WebSpace Client v5.1 - Additional Single User

20AD1P1A3AYYAEC0 PowerFlex 70 AC Drive 20A

20DC8P7A0EYNANANK PowerFlex 700S AC Drive 8.7 A 4 kW 20D

20P21AD1K1RA0NNN PowerFlex DC Drive 1162 A

2711-NF1 PanelView Accessory

280-PWRM22G-M14 ArmorConnect 3-PH Power Media drop cable

2 F940GOT-LWD-C 5.7寸黑白顯示 6090.-

1492-MCAA120 20 A UL489 Miniature Circuit Breaker

1494U-FC302R 1494U 30A Class R 250V Fuse Clip

軟啟動(dòng)器 3RW44542BC36

SIMATIC STEP 7 V14 6ES7822-1AA04-0XC2 "Transition Package" PowerPack & Upgrade SIMATIC STEP 7 V5.5 -> 專業(yè)版 V14/2010 Combo + SUS

1585D-M4UBDM-1 Micro D-Code, QD Style Ethernet Media

1756-IG16 ControlLogix 16 Pt 5VDC D/I Module

1797-CEC FlexEx Bus Connector

194E-E32-1753-6A 32 A 194E Load switch

2090-CFBM4DF-CEAA05 MP-Series 5 m Length Feedback Cable

2090-MCNPMP-6S20 MP-Series 20 m Length Power Cable

BC646MBP001 Machine Edition Professional Development Suite with Proficy GlobalCare Complete

GC646VPP700 Proficy GlobalCare Complete for VersaPro Professional Edition - Single User License

HMI-CAB-C105 QUICKPANEL PRINTER CABLE

IC641HBR301 Max-ON Standard Software for 90-30 Hot Stand By Redundancy

IC647IFCLNTCRO001C iFIX iClient Read Only 1 PK Keyed (M1Component Part)

IC660EBA026 Electronic Assembly for IC660BBA026

IC695NKT001CA RX3i Ethernet NIU Kit Conbal Coated includes NIU (IC695NIU001) and Ethernet module (IC695ETM001). ENIU supports two serial ports and 20k of local logic. TheENIU must be installed in a IC695CHSxxx base.

IC756WRE049E-27 Runtime License Windows 25-49 Users English v2.7

FlexLogix System 1794-IB16 24V DC SINK INPUT MODULE, 16 POINT

PLC-5/1771 System D1771-6.5.97 SPI PROTOCOL INTERFACE MODULE USER MANUAL

Process Control 1757-PLXSIFG PLX HW UDC 3000/5000/6300 QUICKBUILDER INTERFACE

Operator Interface 2711P-B10C15D1 PV PLUS 1000, KEY/TOUCH, CNET, DC PS, STD MEM

Support 9307-RSPDEVS SUPT RENEWAL CONTRACT FOR 9307RSPDEV

Support GML-DZR SUPT REINSTATEMENT CONTRACT FOR GMLDZ

Support F1785-L30BSERB FIRMWARE UPGRADE FOR 1785-L30B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300FRU2 RSVIEW32 WORKS 150-1500 UPGRADE IN-SUPT (FR)

RSI Software Products 9701-VWSB250ENU1 RSVIEW SE STATION 25 - 250 DISPLAY UPGRADE

RSI Software Products 9399-L5MAN 9399-L5MAN PLC-5 A.I. SERIES MANUAL SET

Motion Control 2098-IPD-HV150-DN HIGH VOLTAGE DRIVE, 34A/68A, ULTRA5000 DEVICENET

BC646MDA159 View Development /Runtime 1,500 I/O

IC300FOX104 FOX Fiber Optic Base

IC752SKT000 Mature, order Datapanel 150 instead. DataPanel K Starter Kit: Includes Datapanel K (DPK000), download & communication cables, WinCfg, user & programming manuals

MTR-3S65-H-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6114-K232#S Motor brake power straight connector for B0.4/5000is or B0.5/6000is or B1/6000is BM0.5/4000 or BM1/4000 motors

20C-DPI1 PowerFlex 700H DPI Option Kit

20G1ABD485AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-D017N104 PowerFlex 523 7.5kW (10Hp) AC Drive

2711P-T15C4D9 PanelView Plus Terminal

6SE6440-2UC22-2BA1 2.2KW

1492-JKD3TP 2.5 mm Knife Disconnect Terminal Block

1492-WMG3 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44233BC35

緊湊型信號(hào)模塊 6ES7 522-1BH10-0AA0 DQ 16：數(shù)字量輸出模塊，晶體管 DQ 16 x 24 VDC/ 0.5A BA, 25mm 模塊，含前連接器

1585-C4HB-S100 1585 Ethernet Cable

1746-OB16 SLC 16 Point DC Output Module

1788-ENBT FlexLogix/DriveLogix ENet/IP Comms Card

194E-16-C3 194E 3 Pole Terminal Cover

20-PP01082 PLASTIC TERMINAL BASE, FRAME 9

2090-CSBM1DF-14AF50 Kinetix Cable Single DSL 2090-Series

20AC030A3AYNAEC0 PowerFlex 70 AC Drive 30 A at 15 kW 20A

GC-8459-EB-MT Ethernet BIM Workbench, Global Care Only

GQPK2D101L2P 6 inch Monochrome/ GE Fanuc Label/ 24VDC/ CE

IC600DM706RR DP Prom Type 1A Module (DPU)

IC647HSTES10000KM Historian Enterprise Server 10,000,000 Points (M4 Key)

IC647WIMM WIM:Westinghouse IMPACC

IC694ALG232LT Low Temperature. RX3i Efficiency 16-Channel Advanced Analog Voltage Input module provides 16 single-ended or 8 differential b channels. 0 to 10 V (unipolar), -10 to +10V (bipolar) with 16 bit resolution. Advanced diagnostics. Requires Proficy? M

IC756SDV000CS-99 DV Development - Solaris Op Sys, Simplified Chinese, Version 9.9

MicroLogix 1200 System 1762-IF4 4 CHANNEL CURRENT/VOLTAGE ANALOG INPUT MODULE