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現(xiàn)代航空發(fā)動機正朝著高溫、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)動機性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機安全、可靠工作極為重要。通過對傳感器故障件的科學(xué)診斷，探索其失效機理，將有利于傳感器的迭代設(shè)計，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，一般采用 X 射線機，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，容易造成故障點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，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)動機數(shù)控系統(tǒng)的高壓壓氣機進(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，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。最后通過試驗驗證了改進(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)動機數(shù)控系統(tǒng)的高壓壓氣機進(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，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，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工業(yè) CT 系統(tǒng)。該系統(tǒng)具備180 kV 微焦點定向式 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。

試驗時，利用微焦點錐束 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 X 射線源采用了低功率以獲得更小的焦點尺寸，調(diào)節(jié)射線源至故障件的距離以實現(xiàn)高比例放大成像。故障件斷層掃描間距為 0． 05 mm，通過計算機斷層掃描后，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，以及在焊點根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個斷點。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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IC754VGB06CTD VIEW BASIC 6IN TFTTOUCH DC FLAT GEF

MSI-DASH-UNL-43 Unlimited Dashboard Clients-43

SLC/1746 System 1746-R14 REPLACEMENT COVERS FOR SLC5/03,04,05 PROCESSOR MOD

Distributed I/O 1734-OW2 24 VDC COIL N.O. DPST RELAY MODULE

Application-specific products 1803-EEM21E12 EEM,32 PULSES,24V DC,8 ANALOG, 4 TO 20 MA, NEMA 12

Operator Interface 2711E-T10C15 PANELVIEW 1000E TOUCHSCREEN TERMINAL, 10.4" FLAT

Support 9302-BLDR SUPT REINSTATEMENT CONTRACT FOR 9302BLD

Support 9381-PP250ENS SUPT RENEWAL CONTRACT FOR 9381PP250EN

DeviceNet Products 1791D-8V8P DNET 24VDC CBLOCK I/O, 8 IN SOURCE 8 OUT SINK,BASE

RSI Software Products 9301-2SE3350FRE RSVIEW32 RUNTIME 5K (FRENCH)

RSI Software Products 9358-PBV01ENE RSBIZWARE BATCH FOR PLX VIEW ADDITIONAL CLIENTS

Motion Control MPL-B880C-MJ22AA MOTOR,SERVO,76.0NM,1500RPM,MULTI,460V

Silver Series 1398-DDM-009X DRIVE,15A PEAK, ULTRA 100 W/INDEX

HE660CGM224 Genius "C" Programmable Co-processor with (2) RS-232 ports

IC646TPD000 Pro Server Unlimited I/O Point Development and Run Time System

QDA-EDT-05P QuickDesigner Lite 5 Pack (download cabe NOT included)

ST-3118 STXi analog b module 8 Channels, 0~20mA, 12bit

20BC105A0AYNAND0 PowerFlex 700 AC Drive 20B

20F14NC260JA0NNNNN PowerFlex 753 AC Packaged Drive

22A-B2P3H204 PowerFlex 4 0.4 kW (0.5 Hp) AC Drive

140CPS21100 Quantum 電源, 24 VDC, 獨立, 3A

284D-FHD2P3B-10-CR-SB DeviceNet Variable Frequency Drive

CJ1W-IC101 I/O控制單元，CPU機架用

1492-RIFM20F-F120A-2 Connection Products

上位網(wǎng)卡 6GK1561-1AM01 CP5611,PCI 卡，用于臺式機，含 5m MPI 電纜

變送器 3RS17001CD00

1497A-A11-M6-0-N Control Power Transber

1606-XLP15A Power Supply XLP 15 W Power Supply

1764-MM3RTC MicroLogix 1500 with RTC Memory Module

188-K4B250 Miniature Circuit Breaker 25 A

194L-HE6E-375 Actuator Handle For Load Switch

2090-CPBM7DF-08AF60 60 m Length SpeedTec Flexible Cable

2090-XXNPMF-16S60 Kinetix Drives 60m Standard Cable

CB1N-1WPM-0140-AZ Brake cable Alpha and Beta series motor s. 14 meters (replaces 44C742238-004 cable)

GC647SGM001 GCScheduler Series and Groups Module

IC200PKG104 VersaMax Ethernet NIU starter kit with I/O.

IC646TBLCLT005 Proficy Troubleshooter for Inbligent Historian Standard, Enterprise and Corporate Clients Access 5 Users

IC647NCS000 CIMPLICITY HMI Cluster Support Option

IC690CDP002 InfoLink CD Promotional 10 Pack

IC698ACC735 Shielded single slot faceplate, package of six.

IC800VMA072 750 W VersaMotion servo amplifier

SLC/1746 System 1746-IA16 AC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6181P-17TSXPH VERSAVIEW INTEGRATED DISPLAY COMPUTER 17-INCH TFT

Application-specific products 9358-PBPCNT03ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 03 UNITS

Operator Interface 2711-K5A3L3 PV550 MONOCHROME KEY, DH485 & RS232 PRINT

Support 9301-2SE2100R SUPT REINSTATEMENT CONTRACT FOR 93012SE2100