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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(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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Motion Control 1326AB-B410J-S2L MOTOR,SERVO,460V,2.7NM,7250RPM,SINGL,IP67

2225 Greyline OS, 4 Line, (20) 4MM Chars, LCD. ASCII /Serial Interface, NEMA 4

HE800ACC012 Cage-clamp (screw) style I/O plug, 12-terminal. (Qty 1)

IC693ACC317 Connector Kit, 24 Pin, Qty (10), Crimp Type (For MDL654, 655, 752, 753)

QPK3D200C2P/B QUICKPANEL 6" TFT COLOR BLANK

TGT-000A-4-0 Target series 4-axis motion control module

SCC-AO10

Stradis SDM280e

SBC 92-506396-003 PCA-0166-00

JEVSA-YV250

HG2-6300P

MK300-PIO16/16

1492-SPM1B500 MCB Supplementary Protector 50 A

直流電源 6EP1437-2BA10 3 相 400-500VAC 輸入，24VDC/40A 輸出

電機(jī)啟動(dòng)器 3VU13400MF00

1497D-A16-M10-0-N Gen Purpose Transber

1608G-3F1 I-Grid 3-Channel Subbion Renewal

1769-OB32 CompactLogix 32 Pt 24VDC D/O Module

190S-AND2-CB40D-TE 2.5-4.0 A Compact Comb Starter W/Ckt-Bkr

194R-N60-1753 Non-Fused 194R Disconnect Switch

2090-CPBM7DF-16AA15 MP-Series 15m Standard Cable

2090-XXTFMP-S09 MP-Series 9 m Length Feedback Cable

CBL-T7-MP-10 Power cable for MTR-3T10 or MTR-3T20 or MTR-3T40 series servo motors. 10 feet

GF-3090R Connecting FlashCable to Denver Instruments, Omega, Tohnichi.

IC200UDR001-24 Qty of 24, 14 point PLC, (8) 24VDC In, (6) Relay Out, 120V/240 AC Powe r Supply

IC646TPR915 ProServer 1,500 I/O Point Runtime System

IC647PATAXIM Proficy PAT - Axiom Multiplexer Interface: Provides The Capability To Control An Axiom Analytical Fmx Series Fiber-Optic Multiplexer

IC693ALG442RR Analog Combo Module, 4In/2Out

IC752ECD400RR Display Station 1462 - 14 inch VGA (640x480) resistive touch screen/ Penti um 133/ 32MB/ 1.2 Gig hard drive/ expansion slots/ Ethern et/ with CIMP LICITY HMI and Win 95

IFIXONNODE300M iFIX Upgrade to On-Node 300 Tag Standard Edition Historian with Alarm & Event Option, M4 Key

SLC/1746 System 1747-DCM DIRECT COMMUNICATION MODULE FOR PROGRAMMABLE CTRLR

Industrial Computers 6186-M20AL VERSAVIEW 20 INCH MONITOR, TEMPERED GLASS

Application-specific products 1404-M505A-232 MASTER MODULE - PQ 232 COM

Operator Interface 2711-T6C9L1 PV600 COLOR TOUCH, RS232 (DH485) & RS232 PRINT

Support 9301-2SE3100PTS SUPT RENEWAL CONTRACT FOR 93012SE3100PT

Support 9380-RSBEDEQPR SUPT REINSTATEMENT CONTRACT FOR 9380RSBEDEQP

DeviceNet Products 1738-ADN12 DEVICENET ADAPTER M12

RSI Software Products 9301-2SE3200ZHU1 RSVIEW32 RUNTIME 150-300 UPGRADE IN-SUPT (ZH)

RSI Software Products 9358-BPCNT60U1R UPGRADE: OUT-SUPT: RSBATCH PC-BASED 03 TO 60

Motion Control MPL-B4520P-SJ24AA MOTOR,SERVO,6.1 NM,5000RPM,SINGL,460V,BRK,9.5KG

Motion Control 2090-SCVG150-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,150.0M

GFK-2251 Panel C Industrial Computer User's Manual

IC646MGRS10 Electronic Signature option for a 10 users Procify Change Management system.

MTR-1324-E-D-E-0 Stepping Motor Nema34, Series Wdg, Encoder

QPICTAE0000 10.4 inch Color TFT/ TCP/ Ethernet/ CF Card/ 110VAC

PXIe-5162

MM-5425/512

IOWA-8522

NORCO-690AE

P600VL-D73E