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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(chēng)“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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安裝導(dǎo)軌 6ES7390-1AF30-0AA0 安裝導(dǎo)軌，530 mm

變送器 3RS18001HQ00

TIA 博途 WinCC 選件 6AV2107-2LF00-0BD0 SIMATIC WinCC DataMonitor for Runtime Professional Powerpack 3 -> 10 Clients

1585J-M8PBJM-15 RJ45 Ethernet Media

1760-L12NWN-ND Pico 12 Point Controller

188-K2C250 Miniature Circuit Breaker 25 A

194L-A40-1754 40 A 194L Load Switch

2090-CNSRPRS-AA15 Kinetix 6000M network cable

2090-XB33-32 33 Amp 32 Ohm Resistive Brake Module

BC647MRA159 View Runtime 1500 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFUBSTS GCC iFIX iClientTS User Base Support

IC200CPUE05CA Conbal coated CPU with built-in Ethernet 10Mbits, one RS 232 and one RS 485 port.

IC646NCN010 HMI for CNC Option

IC647IFSTRNUNLMTC iFIX Standard HMI Unlimited Runtime (M1Component Part)

IC670MDL233RR 120VAC 8 pt. Isolated Input

IC697MDL241 240 Vac Isolated Input (16 Points)

IC800SLCBV100 Power/brake cable for SLM100 or SLM250 S-series servo motor with brake. 10 meters

ControlLogix/1756 System 1756-DMAF 2-RE PMI FIBER OPTIC CABLE ADAPTERS

Industrial Computers 6182H-12BRH6D VVCE 1250, KEY/TOUCH, STD MEM, RIO/DH, DC

Process Control 1757-PFBEXP035 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RN6 PV PLUS DH+/RIO/DH-485 COMMUNICATION MODULE

Support 9357-ANETMD3R SUPT REINSTATEMENT CONTRACT FOR 9357ANETMD3E

Support 9361-DATAOCXS SUPT RENEWAL CONTRACT FOR 9361DATAOCX

ControlNet Products 1734-OB2E 24V DC 2 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE2400U4 UPGRADE: IN-SUPT: WINVIEW TO RSVIEW32 WORKS 32K

RSI Software Products 9357-DNETMDAD3E RSNETWORX MD FOR DEVICENET ADD-ON

Motion Control MPL-A420P-HK22AA MOTOR,SERVO,4.74NM,5000RPM,ENCDR,230V,5.0KG

Motion Control 2090-UXNFBMP-S30 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,30M

CBL-13-ED-30 Encoder Cable, MTR-1235, 13xx, 14xx & 1N Series Stepping Motors to IMC-D or S2K, 30 Ft.

IC600WD200 I/O Cable, 200 feet (60m)

IC800SKCPVL050 Power Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 5 Meters

OC647IFFDTPC iFIX Optn: Fix Desktop (M1Component Part)

20AD1P1A0AYNANC0 PowerFlex 70 AC Drive 20A

20DC820ACENNBNANE PowerFlex 700S AC Drive 820 A 450 kW 20D

20P21AD086RA0NNN PowerFlex 86 A DC Drive

2711-ND3DEM PanelView ND3DE MED Accessory

280-PWRM22G-M05 ArmorStart Three-Phase Power Media

35 FX-EEPROM-8 EEPROM存儲(chǔ)卡8K/步,適用FX2N 620.-

1492-MC6X5 IEC 6 x 5 mm Marker Card

1494U-F60 1494U 60A Fuse Block

軟啟動(dòng)器 3RW44542BC34

SIMATIC STEP 7 V14 6ES7822-1AA00-0YL5 SIMATIC STEP 7 專(zhuān)業(yè)版 TIA Portal SUS

1585D-M4UBDF-5 1585D Ethernet Media Patchcord

1756-IF8I ControlLogix 8 Point Analog Input

1797-BIC FlexEx Accessories

194E-E25-1753-6N 25 A 194E Load switch

2090-CFBM4DF-CDAF40 MP-Series 40m Feedback Cable

2090-KPBM7-06AA MP-Series Power and Brake Connector Kit

BC646EXM365 Solution Provider additional ME License

GC646TRT915 Proficy GlobalCare Complete for Server 1500 I/O Runtime System

HMI-CAB-C101 CABLE SIMATIC TI 500 SERIES 9 PIN PROGRAM PORT

IC641GBE671 PCIM Driver Software Source Code (Microsoft C)

IC647IFCLNTCDVM iFIX iClient Development (M4 Part)

IC660EBA024 Electronic Assembly for IC660BBA024

IC695MDL664 Smart Digital 24VDC Input module, 16 b channels in two groups of eight. Module does not ship with terminal block. IC694TBB032 or IC694TBSx032 terminal block is required.

IC756WRE024K-99 DataViews Runtime for Windows 1-24, Per User, Korean, Version 9.9

FlexLogix System 1794-IA8 85-132 VAC INPUT MODULE, 8 POINT

PLC-5/1771 System D1771-6.5.91 ISOLATED ANALOG INPUT MODULE USER MANUAL

Process Control 1757-PLXSIFC AB RSLINX QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6D1 PV PLUS 700, TOUCH, RIO/DH, DC PS, STD MEM

Support 9307-RSP32RENS SUPT RENEWAL CONTRACT FOR 9307RSP32REN

Support GML-DSR SUPT REINSTATEMENT CONTRACT FOR GMLDS

Support F1785-L26BSERC FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESU1 RSVIEW32 WORKS 300-1500 UPGRADE IN-SUPT (ES)