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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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2090-XXNPMP-14S09 MP-Series 9 m Length Power Cable

CBL-13-MP-30 Power cable for MTR-1220 or MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors. 30 feet

GC647WFL025 Proficy GlobalCare Complete for Proficy Workflow - 25 User License

IC200SET001 Ethernet to Serial Interface

IC646TBLSS40K Proficy Troubleshooter for Inbligent Historian for Hist 40000 Points

IC647NMB000 MODBUS PLUS OPC Server

IC693ACC306 EPROM Chips (qty 4)

IC698RMX016CA RX7I REDUNDANT MEMORY EXCHANGE 16MB CONFORMAL COATED

IC800VMCB2100 Motor power and brake power cable for 2 kW VersaMotion servo motor- 10 meter

SLC/1746 System 1746-OA16 AC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-14SXPH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBK2DC SLC FIXED CLUTCH/BRAKE KIT DC I/O

Operator Interface 2711-T5A5L1 PV550 MONO TOUCH, RS232 (DH485)

Support 9301-2SE2300ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300ES

Support 9307-64MGDBCS SUPT RENEWAL CONTRACT FOR 930764MGDBCENE

DeviceNet Products 1732D-OB8EM12 DEVICENET 24VDC 8 0.5A OUTPUT W/M12

RSI Software Products 9301-2SE250ITU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT (IT)

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Motion Control MPL-B310P-SK22AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V

Motion Control 2090-XXNPY-16S09 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,9M

GFK-0256 MegaBasic Language Reference and Programmer's Guide

IC641VPH700 VersaPro Professional Edition - Windows Programming Software with Programming Cable for Series 90-70, Series 90-30, and VersaMax PLCs

IMC-316X-X-D IMC-D Series Servo Motor Controller, 6 Amp

PSPC-DC25-220 Prof Shop Floor SPC DC 25 User 220v

20BC011A0AYYANC0 PowerFlex 700 AC Drive 20B

20DM325N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H070-AD-T K5500 FR3 AC,DC Bus Connector

2711P-RAK12E PanelView Plus Accessory

280-PWRM35G-M2 ArmorStart Three-Phase Power Media

CQM1H-ABB21 絕對值編碼器 2點

1492-MUA2B-A7-A10 1772 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1AH02-0AE0 CP340，標準串行通訊模塊，RS232C 接口，最高19.2kbit/s,9 針 Sub-D 接口

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TIA 博途 WinCC 選件 6AV2107-0CR00-0BB0 SIMATIC WinCC Sm@rtServer for SIMATIC Basic Panels

1585J-M8HB-2 RJ45 Ethernet Media

1756-SYNCH ControlLogix SynchLink Comms Module

188-K1D320-N Miniature Circuit Breaker 32 A

194E-Y32M-1753-6N 32 A 194E Load switch

2090-CFBM7E7-CEAF12 Kinetix 12m Extension Cable