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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)的高壓壓氣機進口總溫傳感器的故障現(xiàn)象，利用工業(yè) CT 技術(shù)對其進行了無損檢測，從而快速、準確地定位到故障點，并利用其提供的傳感器內(nèi)部信息對故障原因進行了分析，采取了相應(yīng)的改進措施。最后通過試驗驗證了改進措施的有效性，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，始終未能準確地定位故障點，無法對傳感器進行結(jié)構(gòu)和工藝上的改進，嚴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，細節(jié)分辨能力可達 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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1756-N2XT ControlLogix XT Empty Slot Filler

188-K1B100-N Miniature Circuit Breaker 10 A

194E-FA40EX-PE-TN 194E Load switch

2090-CFBM7DD-CEAF30 Kinetix 30m Flexible Cable

2090-U3BK-D4401 Ultra 3000 Breakout Board Kit

BC646MRC000 Logic PC and View Runtime 8000 I/O with Proficy GlobalCare Complete

GC647ASC010 GC SDK 10 Pak

IC200ACC202 Expansion terminator, quantity 2

IC646CGMV00 CIMP Viewer GM Site License (SW Key)

IC647IFPLRN00300C iFIX Plus SCADA 300 I/O Runtime (M1Component Part)

IC660MKS511 Hand-Held Monitor Spare Key (Qty 10)

IC697ADS701 CIMPLICITY 90-ADS Package (First System)

IC756XRT099 Inb x86 DV Tools Runtime 50-99, Per User

FlexLogix System 1788-CNC CNET LOGIX DAUGHTERCARD - COAX MEDIA

GuardPLC Systems 1753-IB16 GUARDPLC DISTRIBUTED I/O - 16 IN, GUARDPLC ENET

Process Control 1757-UPGSIFM UPGRADE GEC GEM80 PLC QUICKBUILDER I/F

Operator Interface 2711P-T12C15B1 PV PLUS 1250, TOUCH, CNET, AC PS, STD MEM

Support 6643-P3A0S 6643-P3A0 SOFTWARE SUPPORT RENEWAL

Support 1784-DPR SUPPORT PLAN 1784-DP REINSTATEMENT

Support F1785-L86BSERC FIRMWARE UPGRADE FOR 1785-L86B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350FRU3 RSVIEW32 WORKS 1500-5K UPGRADE IN-SUPT (FR)

RSI Software Products 9701-VWSS250JPU1 RSVIEW SE 25 TO 250 UPG JAPANESE

RSI Software Products 9399-WAB32LUGIT RSLINX LITE USER GUIDE (ITALIAN)

Motion Control 8720MC -D078-AN- 78 AMP C CHASSIS DRIVE, OPEN ENCL., LESS OPTIONS

BC646MRA075 View Runtime 75 I/O

IC300OCS990 Starter Kit includes IC300OCS035 and IC300OSW232. No simulator. Limited one per customer

IC752WTE050 Display Station 2000 Series - 10.4" active matrix VGA (640x480) resistive touchscreen, Pentium 333MHz, 128MB RAM, 6.4 GB HD, Ethernet, 300pt count CIMPLICITY HMI, field detachable front/rear housing and Win NT

MTR-3T44-J-R-0-M-0-MODRR Servo Motor MOD=Keyway

20AC8P7A0AYNNNC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC011A3NYNACASE PowerFlex 700S AC Drive 20D

20G1ALD617AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D030N104 PowerFlex 525 15kW (20Hp) AC Drive

2715-B10CA PanelView 5500 10.4 in. Graphic Terminal

FR-E540-5.5K 10KVA 13A 5.5KW 3相AC380V/50Hz/60Hz

1492-L6T-B IEC Term Blck 8.1x90x38mm Spr Clp

1494F-D400 Disconnect Switch

軟啟動器 3RW44346BC34

ET 200SP 6ES7155-6AA00-0BN0 IM 155-6 PN 標準型PROFINET接口模塊，含總線適配器 BA 2xRJ45

1585D-D4TBJM-0M6 Micro D-Code, QD Style Ethernet Media

1747-M15 SLC EEPROM Memory Module Adaptor

1794-ADNK Flex DeviceNet Adaptor

194E-AA16E 194E Load switch