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現(xiàn)代航空發(fā)動機(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)動機(jī)性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機(jī)安全、可靠工作極為重要。通過對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)的傳感器故障檢測方法存在下列局限性: 1) 無損檢測時(shí)，一般采用 X 射線機(jī)，僅適用于對傳感器的金屬結(jié)構(gòu)進(jìn)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(jìn)行分解以查找故障點(diǎn)，容易造成故障點(diǎn)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(zhǔn)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(yīng)用［3 ～ 7］。工業(yè) CT 的上述特點(diǎn)，使其成為傳感器故障無損、準(zhǔn)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(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)對其進(jìn)行了無損檢測，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手段，始終未能準(zhǔn)確地定位故障點(diǎn)，無法對傳感器進(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 檢測設(shè)備與試驗(yàn)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(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(yàn)時(shí)，利用微焦點(diǎn)錐束 CT 對傳感器故障件進(jìn)行檢測。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(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。

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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HE693TCR050 Mini SNP unit, LCD display, 5Vdc power, (use HE693CBL150)

IC630CHS304RR Base Unit, 4 Slots

IC647HSTSS250KM-35 Historian v3.5 Standard Server 250000 Points (M4 Key)

IC660BBS103 Block 115Vac/125Vdc Low Leak Isol I/O, w/o Failed Sw Diag, 8 Ckt

IC695ALG600CA Conbal Coated Universal Analog Input module. Terminal block not included.

IC756WDS001E-28 DataViews Devel Suite for Visual Basic, Java, C++, Native C, Custom Editor, English, v2.8

CompactLogix System 1769-OW8I 8 PT. VAC/VDC INDIV. ISOLATED RELAY OUTPUT MODULE

PLC-5/1771 System 9399-EMMAN PLC-2,-5,-500 PROCESSOR EMULATION GUIDE

Distributed I/O 1799-DNC5MMS DNET 5-POS. TO MICRO MALE CONNECTOR (LOTS OF 5)

Operator Interface 2711P-T6C1D PV PLUS 600 COLOR, TOUCH, SRIO, DC PS

Support 9325-S5255R SUPT REINSTATEMENT CONTRACT FOR 9325S5255

Support 9358-PBEPB30S SUPT RENEWAL CONTRACT FOR 9358PBEPB30ENE

Support F1779-KFLSERA FIRMWARE UPGRADE FOR 1779-KFL COMMUNICATION MODULE

RSI Software Products 9301-2SE2100KOE RSVIEW32 WORKS 150 (KOREAN)

RSI Software Products 9701-VWMR075ADEE RSVIEW ME STATION RT 75 DISP-WINDOWS 2000 (GERMAN)

RSI Software Products 9361-PTL50USR RSPORTAL PER CONNECTION LICENSE FOR 50 CONNECTIONS

Motion Control 2098-DSD-020X DRIVE, 10A/30A,ULTRA 3000

A290-0571-T053 Motor Fan Kit, Alpha 12 and Alpha 30 Motors

IC200UEX626 6 channel Analog expansion. (4) Analog bs & (2) Analog Outputs, 24VDC Power Supply (*includes IC200CBL501)

IC752DEM000 Mature Products, order QuickPanel instead.DataPanel Demo Kit A

MTR-3N33-H-R-B-N-SRR Servo Motor Nema34 24V Brake, Seal

ZA06B-0247-B200#0100 A22/3000i Servo Mtr IP67 Sgt Shft/Key,1M

20BD8P0A3AYYACC1 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14ND125AA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-D037 PowerFlex 520 18.5kW (25Hp) Power Module

140CPU67160S Quantum 安全型熱備CPU

FRN0.4G11S-4CX 1.1KVA 1.5A 0.4 KW 3相AC380V/50Hz/60Hz

1492-J4-Y 4 square mm Feed-Through Terminal Block

1492-SPM3D320-N MCB Supplementary Protector 32 A

軟啟動器 3RW40562BB44

配件 6GK7 277-1AA10-0AA0 "CSM 1277 以太網(wǎng)交換機(jī) - 4 端口

150B-SC3FBD-BP Encl. SMC-50 150B- Motor Controller

1738-OB16E19M23 ArmorPoint 16 Point Output Module

1784-SD1 ControlLogix Secure Digital Card

193-NCXP-AIO-CNT E300 Analog Module Connectors

20-750-RPD1-F8 PowerFlex 750 Remote Pod Mounting Kit

2090-CSBM1DE-14AF09 Kinetix Cable Single DSL 2090-Series

20AB6P8C3AYNANC0 PowerFlex 70 AC Drive 6.8 A at 2 Hp 20A

GA647IFPRRNUNLMT GCA iFIX Profsnl SCADA Unlmt Run

GP647IFESGSR00150 GCP iFIX Optn: ESig & ERec 150 I/O Srv

IC600BF909RR 48Vdc Source Output Module (8 points)

IC647HSTCR150KM Collector Redundancy Option for Historian - Standard Server 150000 Points (M4 Key)

IC647TPD075 CIMPLICITY HMI ProServer 75 I/O Development & Runtime System

IC693PCM300MP Prog. Coproc. Mdl., 160Kb (35Kb Basic Prgm), w/Port Exp. Cbl. Modified for use by OEMs

IC756LDV010K-97 DV Draw Development on Inb/Linux RedHat Op Sys, Korean, Version 9.7

MicroLogix 1000/1761 System 1761-L20AWA-5A 25 I/O MICROLOGIX 1000 WITH ANALOG

PLC-5/1771 System 1771-IFEK CONFORMALLY COATED, ANALOG INPUT MODULE, 12 BIT

Distributed I/O 1792D-16BVT0D 16 SINK/SOURCE INPUTS, 8 CONNECTORS

Communications 9300-KF2RAD REMOTE ACCESS KIT FOR DH+

Operator Interface D6190-6.5.10DE CONTROLVIEW EVENT DETECTOR USER MANUAL (GERMAN)

Support 9356-SQLSAP200S SUPT RENEWAL CONTRACT FOR 9356SQLSAP200

Support 1789-SLXR SUPT REINSTATEMENT CONTRACT FOR 1789SLX

EtherNet/IP Products 9351-VS INTERCHANGE FOR OPENVMS

RSI Software Products 9301-2SE3500ITU3 RSVIEW32 RUNTIME 300-100K UPGRADE IN-SUPT (IT)

RSI Software Products 9356-PRO2500U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO PROF.70000 TG

Motion Control N-5647-2-H00AA MOTOR,NEMA 56,47 LB-IN,3000 RPM

44A731246-G05 APM301 Firmware Upgrade Kit to V2.70

IC200BEM103 PLC NETWORK COMMUNICATION DeviceNet MASTER

IC694ALG221 INPUT MODULE ANALOG 4 POINT CURRENT