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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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IC200MDL241 INPUT 240VAC (2 GROUPS OF 8) 16PT

IC697CMM731RR Series 90-70 Broadband Lan Interface, All Channels (MAP 30)

MTR-1324-0-D-E-0RR Stepping Motor Nema34 Double Shaft

Z44B295864-001 DSM controller 11slot grounding bar

20BD096A3ANNANC0 PowerFlex 700 AC Drive 96 A 75 Hp 20B

20G11NC2P1AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-D4P2N103 PowerFlex 4M- 1.5 kW (2 HP) AC Drive

NWBM85S232 Quantum multibridge, MB+/4 RS232, user programma

294D-FD4P2Z-G1-3 Variable Frequency Drive

S82J-30024 120V/240VAC可選。容量：300W輸出24V 12.5A

1492-SPM3B070 MCB Supplementary Protector 7 A

軟啟動(dòng)器 3RW40271BB15

電機(jī)啟動(dòng)器 3VU16403CM00

150-F60FBD Encl. SMC Flex Smart Motor Controller

1734-EPAC POINT I/O Extension Power Module

1783-BMS10CGA Stratix 5700 10 Port Managed Switch

193-EIO-CM-C23 E300/E200 100-C23 Contactor Coil Module

20-750-CBPEMCCM1-F8 PowerFlex 750 Kit,DC,Com Mode Core,Fr8-9

2090-CPWM7DF-10AF25 MP-Series 25 m Length Power Cable

2098-DSD-005-DN Ultra 3000 Servo Drive

FC-SW-750 Fieldcare PRO with Full License (750)

GFK-2070 10.5 inch/12.1 inch 110VAC QuickPanel Installation Guide

IC220PBI001 PROFIBUS-DP NETWORK INTERFACE UNIT (REQUIRES 1 IC220TBK087)

IC647DMS003 DataMart 3 PA Connections

IC647ROC002M ROC:Fisher Remote Operations Controller for 10 Units

IC693MDL350 120/240 Vac Isolated Output, 2 Amp (16 Points). Module requires a terminal block (IC694TBBx32 or IC693TBSx32).

IC756CDV010J-99 DV Draw Development on Compaq True64, Japanese, Version 9.9

MSI-PROD-50-43 Product Mang Clients 50 Pack-43

PLC-5/1771 System 1785-BCM PLC-5 BACK-UP COMMUNICATIONS MODULE

Distributed I/O 1790-T0B16X LDX I/O, 24VDC, 16 SOURCE OUT EXPANSION, TERM BLK

Communications 1785-TBM THICK-WIRE TRANSCEIVER CABLE KIT, 49.2FT/15M, STD

Operator Interface 2711-NM3 EEPROM CHIP FOR STORING PANELVIEW 1200 CONFIG.

Support 9305-RSVADDCFRR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADDCFR

Support 9324-RLD300ITS SUPT RENEWAL CONTRACT FOR 9324RLD300IT

DeviceNet Products 9355-RSLETENE RSLINX ENTERPRISE

RSI Software Products 9301-2SE3400FRU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (FR)

RSI Software Products 9371-RSWD1U1 UPGRADE: IN-SUPT: RSWIRE DET JIC STDAL TO DES PRF

Motion Control 1326AB-B410G-M2L MOTOR,SERVO,460V,2.7NM,5000RPM,MULTI,IP67

2125 Greyline OS, 4 Line, (20) 5MM Chars, VFD, Quick Connect, NEMA 4

HE693XTADP 9-pin to 25-pin adapter for HE693SNPCBL, HE693CBL222 and 25-pin serial ports

IC677DBM442 Profibus VersaMax IP Modular slave with (8) 24VDC bs

QPK2D100L2P/S QUICKPANEL MONO 6" LCD WITH EPOXY SEAL

STXPBS925 STXi Profibus with 16 24VDC source (Negative Logic) b and 16 isolated relay output, expandable to 8 additional modules.

20BC3P5A0NYNANC0 PowerFlex 700 AC Drive 20B

20F1AND302AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-D012F104 PowerFlex 40 5.5 kW (7.5 Hp) AC Drive

140DIO33000C Quantum 開關(guān)量輸出, 8點(diǎn), 本安型,CC

284E-FVD2P3Z-10-DRN-DB1-SB-EMI EtherNet Variable Frequency Drive

E3Z-R81 4m 反射式 晶體管輸出 PNP 100Ma 電源DC12-24V

1492-SPM1B300 MCB Supplementary Protector 30 A

直流電源 6EP1336-3BA00 120/230VAC 輸入，24VDC/20A 輸出

6SL32101KE175UF1

1497D-A15-M10-0-N Gen Purpose Transber

1606-XLSRED80HE XLS Redundancy Module

1769-L36ERM CompactLogix 3 MB Motion Controller

190S-AND2-CB10C Compact Comb Starter W/Ckt-Bkr

194R-LNC8 Terminal Shroud, 4P, 125A

2090-CPBM7DF-16AA03 MP-Series 3m Standard Cable

2090-XXNPY-16S25 Y-Series 25 m Length Power Cable

CBL-OIJR-06-RA Serial cable with right angle connector for Operator Interface Panel connected to an S2K controller. 6 feet

GF-2530R Connecting FlashCable to Sony LH xx (w/RS-232).

IC200UDD120 28 point PLC,(16) 24VDC In, (12) 24VDC Out ESCP(2 at 1.0 amp and 10 at 0.70 amp), 24VDC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC646TPD935 35,000 I/O Point Development System

IC647OPMC OPM:Opto 22 Mistic

IC693ALG392CA Conbal Coated Analog Output module, eight channels voltage/current.

IC752DPJ000RR Datapanel J+, 256x64 LCD with EL backlight. Various sizes of text, bi tmaps, bar graphs, real time clock. Includes an integrated keypad for data entry. No touch capability.

IC800VMMCONP003 VersaMotion motor power and brake connector (1 kW and 2 kW models)

SLC/1746 System 1747-PIC CONVERTER RS 232/DH 485

Industrial Computers 6186-M15SSTR VERSAVIEW 15 INCH MONITOR, RESISTIVE TOUCH SCREEN

Application-specific products 1404-M405B-232 MASTER MODULE - PQ 24V POWER SUPPLY 232 COM

Operator Interface 2711-T6C20L1 PV600 COLOR TOUCH, ENET & RS232 PRINT

Support 9301-2SE3100ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE3100IT