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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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20G14TC750JN0NNNNN PowerFlex 755 AC Packaged Drive

25-RF8P0-BL PowerFlex 520 8.0A 600V EMC Filter Kit

2711P-T10C21D8S-B PanelView Plus 7 Standard 1000 Brandless

FRN 5 5P11S-4CX 8 5 KVA 112A 55KW 3相AC380V/50Hz/60Hz

1492-JD3FB 2.5 square mm Double Level Fuse Block

1492-W3-Y IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW40756BB45

安全 CPU 模塊 6ES7 516-3FN01-0AB0 SIMATIC S7-1500F，CPU 1516F-3 PN/DP，中央處理單元，帶有：1.5 MB 工作存儲(chǔ)區(qū)，5MB 數(shù)據(jù)存儲(chǔ)區(qū)

156-B25AB2 25 A Contactor

1746-HSCE SLC High Speed Module

1786-RPFRL CNet Fiber Ring Long Distance Repeater

193-T1AC12 9.0-12.5 A IEC Bibllic Overload Relay

20-FR09824 RECTIFIER MOD SUB-AS.(WITH BRK) FR9 400V

2090-CSBM1DF-14AA10 Kinetix Cable Single DSL 2090-Series

20AC015A3AYNADG1 PowerFlex 70 AC Drive 20A

GA647TPD700 Proficy GlobalCare Assist for CIMPLICITY HMI ProServer 700 I/O Development and Runtime System

GP647IFPRSR00150 GCP iFIX Profsnl SCADA 150 I/O Srv

IC600CB508RR 1K Register Memory Module (for use in Model 600 or 6000)

IC647HSTCS30KM Historian Enterprise Corporate Server 30000 Points (M4 Key)

IC647TSSRV005 Proficy Troubleshooter 5 User Server License

IC693PWR330RR Power Supply, 120/240 Vac, 125 Vdc, High Capacity

IC756RDV000E-97 DV Development - Irix Op Sys, English, Version 9.7

MicroLogix 1000/1761 System D1761-6.4 AIC + ADVANCED INTERFACE CONVERTER USER MANUAL

PLC-5/1771 System 1771-OFE1K CONFORMALLY COATED, ANALOG OUTPUT MODULE

Distributed I/O 1794-APB 1794-APB 12 MBPS PROFIBUS DP ADAPTER FOR FLEX I/O

Communications 9355-RSLETENE RSLINX ENTERPRISE

Operator Interface D6190-6.5.4DE CONTROLVIEW ALARMING USER MANUAL (GERMAN)

Support 9358-BBKEY03R SUPT REINSTATEMENT CONTRACT FOR 9358BBKEY03ENE

Support 9392-KBCDRSR SUBSCRIPTION RENEWAL FOR KNOWLEDGEBASE CD

RSI Software Products 9324-RL01U3ENER UPGRADE: OUT-SUPT: RS500 STARTER TO RS500

RSI Software Products 9301-2SE3500U5R UPGRADE: OUT-SUPT: RSVIEW32 RUNTIME 5000 TO 100K

RSI Software Products 9356-STD2350U1R UPGRADE: OUT-SUPT: RSSQL STD 150 TO STD 5000 TAG

Motion Control Y-1003-1-H04AA MOTOR,SERVO,0.35 NM,4500RPM,ENCDR,115V,BRK,1.2KG

5004S Obsolete - Message Center. 1 Line, 15MM, Green VFD. SLAVE Unit. NEMA 4

IC200CHS122 I/O INTERPOSING FUSE STYLE, 16 PT EXPANSION

IC694MDL753 OUTPUT MODULE 12/24 VDC 0.5AMP 32 POINT POSITIVE LOGIC

MSI-WEB-2-43 Web or Excel Reping Clients 2 Pack-43

VSPCSE-ATNT VisualSPC SE Audit Trail Monitoring and Notification Tool.

20BD052A3AYNACC1 PowerFlex 700 AC Drive 52 A 40 Hp 20B

20G11LC1K5JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-E019N104 PowerFlex 40P 11 kW (15 Hp) AC Drive

140ESI06210C Quantum ASCII 接口模塊, RS232, 2通道, CC

291D-FAP-G1-3FR Direct Online Reversing Starte

MK4NJ-D2 NEW 24VDC，有反向二極管，4開(kāi)4閉，觸點(diǎn)5A 中國(guó)制

1492-SPM2C500 MCB Supplementary Protector 50 A

軟啟動(dòng)器 3RW30362BB04

電機(jī)啟動(dòng)器 3VU16403LS00

150-F251NBR SMC Flex Smart Motor Controller

1732E-16CFGM12P5QCR ArmorBlock 16 Point Configurable QC

1771-P5EK 1771 Power Supply

193-EEDP E1 Plus 3.2-16 A IEC Overload Relay

199-MSMA48 Surge Suppressor

2090-CPWM7DF-08AA90 MP-Series 90m Standard Power Cable

2097-F4 Kinetix 300/350 4.40 A Line EMI Filter

EDS-308-T C1 D2 8-port Unmanaged 10/100 Switch (-40 to 75 deg C op temp)

GFK-1504 Manual VersaMax Modules, Power Supplies, Carriers, and Cables

IC220ALG220 ANALOG IN, 15 BIT, VOLTAGE/CURRENT, 2CH (REQUIRES 1 IC220TBK061)

IC647CGMS00 GM Server Site License (not for general use)

IC647PRTOSIC Proficy Portal OSI PI Connector (M1 Key)

IC693DSM302RR Series 90-30 Motion Mate DSM302 Motion Controller, 2 Axes

IC756ADV001K-97 DV Development - AIX Op Sys Addt'l User, Korean, Version 9.7

MSI-IGC-43 7 Day x 24 Hour Support / GlobalCare-43

SLC/1746 System 1746-RT34 TERMINAL BLOCK FOR THE 1746-NT8 MODULE

Distributed I/O 1738-OB4EM8 24VDC 4 SOURCING OUTPUTS WITH M8 CONNECTORS

Communications 2760-A485 CONNECTOR, DH485 MULTIDROP FOR NEMA TYPE 1 DECODER

Operator Interface 2711-NP2 MOUNTING CLIPS PV600 KEY, 900, 1000

Support 9302-SCAR SUPT REINSTATEMENT CONTRACT FOR 9302SCA

Support 9324-RL5300ITR SUPT REINSTATEMENT CONTRACT FOR 9324RL5300IT