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現(xiàn)代航空發(fā)動機(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(jī)性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機(jī)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(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)的傳感器故障檢測方法存在下列局限性: 1) 無損檢測時(shí)，一般采用 X 射線機(jī)，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(diǎn)，容易造成故障點(diǎn)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(diǎn)，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(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)對其進(jìn)行了無損檢測，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(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(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手段，始終未能準(zhǔn)確地定位故障點(diǎn)，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(yàn)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(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(yàn)時(shí)，利用微焦點(diǎn)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(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(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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OC646IFWTRSLNBSCSP Water Solutions Pk 2008 Basic SP Edition

20AD014A3AYNACC0 PowerFlex 70 AC Drive 14 A at 10 Hp 20A

20DC072A0NYNANBNE PowerFlex 700S AC Drive 72 A 37 kW 20D

20G1AND156AN0NNNNN PowerFlex 755 AC Packaged Drive

25C-B8P0N104 PowerFlex 527 1.5kW (2Hp) AC Drive

280-MTR35-LC ArmorConnect Connection Locking Clip

FX1N-24MT 主機(jī)14點(diǎn)入/10點(diǎn)出?晶體管輸出

1492-M5X10C Connection Products

1494G-GF3N NEMA 1494G Enclosed Disconnect

軟啟動器 3RW44442BC34

ET 200SP 6ES7134-6FF00-0AA1 AI 8xU 基本型，基座單元類型 A0、A1

1585D-M4HBJM-4 Micro D-Code, QD Style Ethernet Media

1756-CFM ControlLogix Config Flowmeter Module

1794-IRT8 Flex 8 Point Thermocouple RTD Module

194E-CA20E-P11-PE 194E Load switch

2080-OV4 Micro800 4 Point Sink Output

2090-CSWM1DF-18AA35 Kinetix Cable Single DSL 2090-Series

20AC5P0A3AYNACC0 PowerFlex 70 AC Drive 5 A at 2.2 kW 20A

GC646MRC150 Proficy GlobalCare Complete for Logic PC & View Runtime 150 I/O

HE693STP113 Discontinued Part. Check with GE IP on migration path.

IC610PER154RR Series One PROM Writer Unit (Snap On)

IC647HSTSS20000KM Historian Standard Server 20,000,000 Points (M4 Key)

IC660BBR101RR Relay Block, Normally Open

IC695ALG312CA Conformal Coated. Isolated Thermocouple Input module provides twelve isolated differential thermocouple input channels. Each channel can be individually configured for inputs from: Thermocouple types: J, K, T, E, R, S, B, N, or C and Voltage: +/-150

IC756WDS000J-28 DataViews Development System for Visual Basic, Java, C++, & Native C & Custom Editor 1 User, Japanese v2.8

CompactLogix System 1769-OB32 1769 32 POINT 24VDC OUTPUT MODULE

PLC-5/1771 System 1785-ACC5LA ACCESSORY KIT FOR PLC-5/11,5/20

Distributed I/O 1799-D10U10BL 24 VDC 20 POINT SRC OUT I/O BOARD WITH LOGIC

Operator Interface 2711P-K6M5A PV PLUS 600 GRAYSCALE, KEYPAD, RS232, AC PS. INCL

Support 9325-L5140S SUPT RENEWAL CONTRACT FOR 9325L5140

Support 9358-PBEPB03R SUPT REINSTATEMENT CONTRACT FOR 9358PBEPB03ENE

Support F1775-S5 FIRMWARE UPGRADE FOR 1775-S5 PLC3 PROCESSOR MODULE

RSI Software Products 9301-2SE2100DEE RSVIEW32 WORKS 150 (GERMAN)

RSI Software Products 9701-VWMR030AJPE RSVIEW ME STATION RT30 DISP-WINDOWS 2000 (JAPANESE

RSI Software Products 9359-PORTP50ENE RSPRODUCTION PORTAL 50 PAGE EXPANSION

Motion Control 2098-DSD-005 DRIVE, 2.5A/7.5A, ULTRA 3000

A06B-6093-K303 Connector Kit, Beta Amplifier Battery (CX5X, CX5Y)

IC200UEX213 28 point expansion. (16) 12VDC In, (12) Relay Out, 12VDC Power Supply (included IC200CBL501)

IC752CTD400RR Display Station - 9.5" active matrix VGA (640x480) infrared touch screen, 16 color support, Pentium 133, 32M, 1.2 Gig hard drive, expansion slots, Ethernet, with CIMPLCITY HMI and Win 95

MTR-3N32-H-R-0-N-SRR Servo Motor Nema34 with Seal

ZA06B-0219-B200 A2/6000HVis Servo Motor Sgt Shaft w/Key

20BD8P0A3AYNACD0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14NC456AN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM2-D010 PowerFlex 520 4kW (5Hp) Power Module

TLXCDSUOFS33 Quantum SMALL OPC SOFTWARE (max. 1000 items)

FRN3.7C1S-4C 6. 9KVA 9.0A 3.7KW 3相AC380V/50Hz/60Hz

1492-J4-BL 4 square mm Feed-Through Terminal Block

1492-SPM3D200-N MCB Supplementary Protector 20 A

軟啟動器 3RW40552BB45

SIMATIC 存儲卡 6ES7 954-8LL02-0AA0 SIMATIC MC 256 MB

150-SS Hand-Off-Auto Metal Selector Sw Kit

1738-IE4CM12 ArmorPoint 4 Point Input Module

1784-PCM2 DIRECT CONNECT CBL 15PIN D SHELL PLC-2

193-NCIO-43-CNT E300/E200 Control Module Connectors

20-750-PNET2P PowerFlex 750 2-port PROFINET IO Kit

2090-CSBM1DE-14AA05 Kinetix Cable Single DSL 2090-Series

20AB4P2A3AYNNNC0 PowerFlex 70 AC Drive 4.2 A at 1 Hp 20A

GA647IFPRDV00900 GCA iFIX Profsnl SCADA 900 I/O Dev

GP647IFESGRN00075 GCP iFIX Optn: ESig & ERec 75 I/O Run

IC600BF903RR 48Vdc Sink Output Module (8 points)

IC647HSTCR1000KM Collector Redundancy Option for Historian - Standard Server 1,000,000 Points (M4 Key)