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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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GFK-1277 Genius Modular Redundancy Flexible Triple Modular Redundant (TMR) System User's Manual

IC646MDD300 Logic Developer PC (HRT) 300 Tag Runtime & Development System

MSP-VOL-IN1 Obsolete - 0-10 VDC in / Pulse out

QPI-IBS-201 Communication Module for 7 inch/ 9 inch/ 10 inch & 12 inch: Interbus-S Slave

PXIe-4339

DSRVR/2

ACE450F AC4-OBA2E-00

FB16M-LS-C2D30-2G1

MORQ/16VD Y7250-00

EM-6330

1492-PD3163 325 A Power Distribution Block

電源模塊 6ES7405-0KA02-0AA0 PS405 輸入電壓 24/48/60VDC 10A

變送器 3RS17051KW00

TIA 博途數(shù)字化選件 6ES7823-0BA00-1DA0 SIMATIC OPC UA S7-1500 large ( CPU-1517 / CPU-1518 (F) )

1585J-M8QBJM-3 RJ45 Ethernet Media

1760-OW2 Pico 2 Point Combination Module

188-K2D400 Miniature Circuit Breaker 40 A

194L-E12-4511 12A 194L Load Switch

2090-CPBM4DF-14AF03 MP-Series 3 m Length Pwr and Brake Cable

2090-XXNBTN-S N-Series to TL-Series Transition Cable

BC647OEM0211 OEM Edge Program Renewal Additional Key - CIMPLICITY

GC647MGM001 Enterprise Adapter for Maximo 5.2 Assisted Support

IC200ETM001CA EXPANSION TRANSMITTER CONFORMAL COATED

IC646NHR000 Redundancy

IC647ITMM ITM:Intermec Barcode Readers

IC670MDL730 24VDC 2A Output, Pos. Logic, 8 Point, Electronic Short Circuit Protect ion

IC697MDL640 125 Vdc Input (16 Points)

IC800SLCPV100 Power cable for SDM100 or SLM100 or SDM250 or SLM250 or SGM450 S-series servo motor. 10 meters

ControlLogix/1756 System 1756-PA75R 85-265VAC REDUNDANT POWER SUPPLY

Industrial Computers 6182H-12TEH6D VVCE 1250, TOUCH, EXT MEM, RIO/DH, DC

Process Control 1757-PFBUPG003 PROFIBUS LIC UPG 3 IOMS

Operator Interface 2711P-RW3 PV PLUS INTERNAL CF W/ OS & ME, 256 MB

Support 9357-ENETL3R SUPT REINSTATEMENT CONTRACT FOR 9357ENETL3

Support 9363-PORTALS SUPT RENEWAL CONTRACT FOR 9363PORTAL

ControlNet Products 1734-SSI SSI ABSOLUTE ENCODER INTERFACE

RSI Software Products 9301-2SE240DEU1R RSVIEW32 WORKS 1500-32K UPGRADE OUT-SUPT (DE)

RSI Software Products 9358-B10UB1R UPGRADE:OUT-SUPT:RSBIZWARE BATCH 10 UNTS TO BUNDLE

Motion Control MPL-A430H-SJ22AA MOTOR,SERVO,6.55 NM,3500RPM,SINGL,230V,6.4KG

Motion Control 2090-UXNFBY-S09 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,Y,9M

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

IC610MDL127RR 230Vac Input (8 points)

IC800SLA3502 3500W, 230VAC SL Series Amplifier

OC647IFGLBLDPNSRVENM iFIX WebSpace Dependent Server Enabler

PXI-2547

ACS-6169VE

PCE-5026

SBC81822

MATROX Meteor-Ⅱ751-0201

ASM 03-20870-22

1492-MCAA235 35 A Ul489 Miniature Circuit Breaker

1494U-LM31 1494U 100A Multi-port Lugs

軟啟動(dòng)器 3RW44556BC34

Safety Advanced V14 6ES7833-1FB14-0YE5 STEP 7 Safety Basic V14 SP1 Upgrade

1585D-M4UBDM-7 Ethernet Media M12, Patchord

1756-IV32 ControlLogix 32 Pt 12/24VDC D/I Module

1797-PS2E2 FlexEx Power Supply

194E-E63-1753-6G 63 A 194E Load switch

2090-CFBM6DD-CCAA09 TL-Series 9m Feedback Cable

2090-SCEP10-0 Kinetix 10-10m Fiber Optic Cable

BC646MFC001 FANUC Ladder IIIC for OpenCNC with Proficy GlobalCare Complete