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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(kāi)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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Operator Interface 2711P-RL7C PV PLUS/VVCE 700 BACKLIGHT REPLACEMENT

Support 9355-WABOEMITS SUPT RENEWAL CONTRACT FOR 9355WABOEMIT

Support 9354-SS505R 9354-SS505 SOFTWARE SUPPORT CONTRACT REINSTATEMENT

ControlNet Products 1734-IB8 24V DC 8 CHANNEL SINK INPUT MODULE

RSI Software Products 9301-2SE2400U1R UPGRADE: OUT-SUPT: RSVIEW WORKS 1500 TO 32K

RSI Software Products 9357-CNETMDAD3E RSNETWORX MD FOR CONTROLNET ADD-ON

Motion Control MPL-A330P-SJ24AA MOTOR,SERVO,4.18 NM,5000RPM,SINGL,230V,BRK,6.1KG

Motion Control 2090-UXNBMP-18S90 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 90 MTR.

CBL-138-2 Cable. Allen Bradley SLC500 1747-KE (RS-232)

IC600WD005 I/O Cable, 5 feet (1.5m)

IC800SKCFLY030 Cable, S2K Aux. I/O Connector to Flying Leads, 3 Meter

OC647IFESGSR00300M iFIX Optn: ESig & ERec 300 I/O Server (M4 Part)

20AD065A0AYNANG0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A

20DC650N0ENNBNANE PowerFlex 700S AC Drive 650 A 355 kW 20D

20P21AD027RA0NNN PowerFlex 27 A DC Drive

2711-NC13 PanelView 5 m Operate Comms Print Cable

280-PWRM22F-M2 ArmorStart Three-Phase Power Media

FX2N-1PG-E 定位模塊

1492-MC5X10 IEC 5 x 10 mm Marker Card

1494U-D100 1494U 100A Switch and Mechanism

軟啟動(dòng)器 3RW44536BC44

SIMATIC STEP 7 V14 6ES7822-0AA04-0YE5 Upgrade SIMATIC STEP 7 基本版 V11..V13 -> V14 浮動(dòng)授權(quán)

1585D-M4UBDF-12 1585D Ethernet Media Patchcord

1756-IF16K ControlLogix 16 Point Analog Input

1794-TBNK Flex Terminal Base

194E-E16-PE 194E Earthing-Grounding Terminal

2090-CFBM4DF-CDAF12 MP-Series 12m Feedback Cable

2090-KPBE7-06AA MP-Series Power and Brake Connector Kit

BC5005TBX0000 15 Inch Inbligence Industrial Computer - Bundled - Perbance Series - w/ Windows XP

GC646TRT050 Proficy GlobalCare Complete for Server 50 I/O RUNTIME SYS

HMI-BEZ-205 Stainless Steel Bezel: 12.1 inch (QPL2xxxx-C2P)/ NEMA 4X

IC641CTL931 Control 90-30 Programmer with Paper Documentation Library

IC647IEC005 IEC 61850 Client - 5000 points

IC660EBA020RR Ph B Analog 24/48Vdc 4 In/2 Out Electronic Assembly

IC695FTB1S132 Fiber terminal Block kit includes the IC695FTB001 base plus two IC694TBS032 high density extended shroud spring style terminal blocks

IC756WRE024J-28 Runtime License for Windows 1-24 Users, Per User, Japanese v2.8

FlexLogix System 1794-ADNK CONFORMALLY COATED, DEVICENET ADAPTER

PLC-5/1771 System D1771-6.5.85 PLASTICS MOLDING MODULE INJECT MODE MANUAL

Process Control 1757-PLXRT10 PROCESSLOGIX 10 USER REMOTE OPERATOR INTERFACE

Operator Interface 2711P-T7C4B2 PV PLUS 700, TOUCH, ENET, AC PS, EXT MEM

Support 9307-RSE32R SUPT REINSTATEMENT CONTRACT FOR 9307RSE32

Support GML-DAS SUPT RENEWAL CONTRACT FOR GMLDA

Support F1785-L20CSERE FIRMWARE UPGRADE FOR 1785-L20C PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE220ZHU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (ZH)

RSI Software Products 9701-VWSB100FRU2 RSV SE STATION 100 TO SE SRV 100 UPG (FRENCH)

RSI Software Products 9399-INTDCUUG INTERCHANGE DEVICE CONFIG. UTILITY USER'S GUIDE

Motion Control 2098-DSD-HV220X-DN HIGH VOLTAGE DRIVE, 47A/94A, ULTRA3000 W/DNET,INDE

BC646MBP001 Machine Edition View for Quick Panel, Professional Dev. Suite

IC300DIQ716 16 DC Inputs (12/24vdc), 12 DC Outputs (5/12/24vdc,o.5A pos. logic with ESCP)

IC752MNL002 Datapanel 100 Series Operator's Manual

MTR-3S63-G-R-0-E-SRR Servo Motor with Seal

ZA06B-6114-K204#S Motor encoder straight connector for all Bis series motors

20BP325A0ANNNNC0 PowerFlex 700 AC Drive 20B

20G1ABC540AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B1P6N104 PowerFlex 523 0.2kW (0.25Hp) AC Drive

2711P-T12W22D9P-B PanelView Plus 7 Graphic Terminal

OPC-F1-LNW(Lonworks)

1492-JG35 35 square mm Ground Terminal Block

1492-WG16S IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44223BC36

性能信號(hào)模塊 6ES7 531-7KF00-0AB0 AI 8：模擬量輸入模塊，AI 8x U/I/RTD/TC ST, ( 支持 4 通道 RTD), 35mm 模塊，不含前連接器

156-B45CB1 45 A Contactor

1746-NI8 SLC 8 Point Analog Input Module

1787-RSCABL 6FT (1.82 M)9-9PIN NULL MODEM RS-232 CBL

193-T1DC90 72-90 A IEC Bibllic Overload Relay

20-IP54RF-600 ROOF, IP54/N12, FOR 600MM WIDE POWERFLEX

2090-CSBM1DF-14AF10 Kinetix Cable Single DSL 2090-Series

20AC022C0AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A