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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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194R-C30-1753 194R Disconnect Switch

2090-CPBM7DF-10AF25 MP-Series 25m Continuous-Flex Cable

2090-XXNPMP-14S15 MP-Series 15 m Length Power Cable

CBL-14-ED-20 Encoder cable for MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series splashproof stepping motors connected to IMC or S2K. 20 feet

GCREINSTATEMENT GlobalCare Reinstatement Fee

IC200TBM002 I/O auxilary box style

IC646TBLSS50K Proficy Troubleshooter for Inbligent Historian for Hist 50000 Points

IC647NME000 CIMPLICITY HMI MITSUBISHI MELSEC Communications

IC693ACC308 Rack Adaptor Bracket/ Series 90-30 10 Slot to 19 inch (Front Mount)

IC750CTR100RR PANELWARE VT 100 Panel Controller

IC800VMCB3030 Motor power and brake power cable for 3 kW VersaMotion servo motor- 3 meter

SLC/1746 System 1746-OAP12 HIGH CURRENT AC OUTPUT MODULE FOR PRGRMMABLE CTRLR

Industrial Computers 6155R-7PXPH VERSAVIEW NON-DISPLAY COMPUTER, 7 SLOT

Application-specific products 6556-SCBK3DC OMEGA - 5/03 CLUTCH/BRAKE DC KIT

Operator Interface 2711-T5A9L1 PV550 MONO TOUCH, RS232 (DH485) & RS232 PRINT

Support 9301-2SE2300FRR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300FR

Support 9307-64MGDBPS SUPT RENEWAL CONTRACT FOR 930764MGDBPENE

DeviceNet Products 1734-ADN 24V DC DEVICENET ADAPTER

RSI Software Products 9301-2SE250JPU1R RSVIEW32 WORKS 32K-100K UPGRADE OUT-SUPT (JP)

RSI Software Products 9358-BNT10U1 UPGRADE: IN-SUPT: RSBATCH 03 TO 10

Motion Control MPL-B320P-MJ22AA MOTOR,SERVO,2.94 NM,5000RPM,MULTI,460V,4.0KG

Motion Control 2090-XXNPY-16S15 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,15M

GFK-0265 Series 90-70 Programmable Controller Reference Manual

IC641VPP710 VersaPro Professional Edition 10 Pack - Windows Programming Software for Series 90-70, Series 90-30, and VersaMax PLCs

MMR-B00P-1M-0 Target 1Mb BBRAM Memory Card

PSPC-DC25/E Prof Shop Floor SPC DC 25 User w/ eSig

20BC011A3AYNACC1 PowerFlex 700 AC Drive 20B

20DM590A0NNNBCANE PowerFlex 700S AC Drive 590 A 560 kW 20D

2198-H070-ADP-T K5500 FR3 AC,DC,control conn

2711P-RAK15 PanelView Plus 1500 Cutout Adapter

280-PWRM35G-M25 ArmorConnect 3-PH Power Media trnk cable

CQM1H-SCB41 串行通訊板 RS-232C 一個(gè)/RS422/485一個(gè)

1492-MUA4-A13-A17 1774 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1CH02-0AE0 CP340，標(biāo)準(zhǔn)串行通訊模塊，RS422/485 接口，最高 19.2kbit/s,9 針 Sub-D 型接口

行程開關(guān) 3SE53220SJ22

TIA 博途 WinCC 選件 6AV2107-0EB00-0BB0 SIMATIC WinCC Server for Runtime Professional

1585J-M8HBJM-0M2 RJ45 Ethernet Media

1756-TBE ControlLogix Deep Terminal Block Housing

188-K1D400-N Miniature Circuit Breaker 40 A

194E-Y40-1756-6G 40 A 194E Load switch

2090-CFBM7E7-CEAF25 25 m Length SpeedTec Extension Cable

2090-UXNPBMP-10S01 MP-Series 1 m Length Power Cable

BC647CSCEMK QuickPanel Control software with Proficy GlobalCare Complete and a hardware key

GC647IFPLSRUNLMT GCC iFIX Plus SCADA Unlmt Srv

IC200CBL655 Mitsubishi Fx 25-pin, RS-422 Cable to DataPanel 45/65/85

IC646MPSS99 Logic Developer PLC Standard Unlimited Seat Site License

IC647IFSTDV00075K iFIX Standard HMI 75 I/O Development (M1 Kit Part)

IC670ALG310 Analog Output, Voltage, 8 Channel, +/-10V, 0 to 10V

IC697CPU782RR CPU, 16 MHz, 12K Discrete I/O, Expandable Memory, Floating Pt

IC800PSHV045 PSM-45HVi 45 kW high voltage power supply kit for Alpha servos

ControlLogix/1756 System 1756-OV32E 10-30 VDC ELEC FUSED SINKING OUTPUT 32 PT (36 PIN)

Industrial Computers 6182H-10KRH4D VVCE 1000, KEYPAD, STD MEM, ENET, DC

Process Control 1757-FIMEXP100 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RDB7C PV PLUS 700, KEY/TOUCH SCREEN DISPLAY MODULE

Support 9355-WABDER SUPT REINSTATEMENT CONTRACT FOR 9355WABDE

Support 9351-WESRTR SUPT REINSTATEMENT CONTRACT FOR 9351WESRT

ControlNet Products 1747-KFC15 SLC CNET SERIAL INTERFACE MODULE

RSI Software Products 9301-2SE2400ITE RSVIEW32 WORKS 32K (ITALIAN)

RSI Software Products 9355-WABOEMEU1R UPGRADE: OUT-SUPT: WINLINX TO RSLINX OEM CD

Motion Control MPL-A320P-HJ22AA MOTOR,SERVO,2.94NM,5000RPM,ENCDR,230V,4.0KG

Motion Control 2090-U3AE-D4409 CABLE,TWO AXISTO LOGIX 1756MOAE2 CARD,9M

CBL-119-1 Cable.SIMATIC T.I. 305 DCU (RS-422)

IC5105KAW0000 15" Inbligence Industrial PC, Panel-C Series Win2000

IC800PCUBC10S030 PowerCube Flying Lead Interface Cable, 1000 Steps/Rev & Power Save Enabled, 3 Meters