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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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RSI Software Products 9358-PLTM2500U2 UPGRADE: IN-SUPT: PLANTMETRICS 10 TO 100 WORKCELL

Motion Control 8720SM-055S5PAS3 55 KW/116AMP,750 VDC, AMP AC MOTOR WITH SNS60 ENC.

995-4-1 Thumbwheel Assembly. 4 Digit. 1 True. Dust Seal

IC200TBX114 Tool box, 14 point (IC200UDR001) 24VDCIn/Relay Out, 24 P/S, VersaMax DataPanel DP45 with Programming software and cables, (IC640VPS00, IC752DDZ000, IC200CBL555)

IC698CHS217A RX7i 17Slot Rack Mt with Read I/O Access

MTR-1350-E-A-E-0 MTR series NEMA 34 stepping motor with parallel winding connection and encoder

ZA06B-0076-B503#0100 B8/3000HVis High Voltage Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD248A0ANNAND0 PowerFlex 700 AC Drive 20B

20G11RC8P7AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-70C PowerFlex 520 Fr A-D Control Module Fan

140XTS10206 Quantum CABLEFAST電纜, 大電流, 帶 I/O 端子, 1.8M

294E-FD4P2Z-G2-3-SB Variable Frequency Drive

D4MC-2020 觸點(diǎn):1開(kāi)/1閉,10A 250VAC機(jī)械壽命:1000萬(wàn)次?下壓式合頁(yè)式滾珠短擺桿型

1492-SPM3C070 MCB Supplementary Protector 7 A

軟啟動(dòng)器 3RW40361BB04

數(shù)字量輸入 / 直流輸出模塊 6ES7 223-1BL32-0XB0 M 1223DI 16×24 V DC，DQ16×24 V DC

150-PB Start/Stop Metal Push Button Kit

1734-OV4E POINT I/O 4 Point Digital Output Module

1783-IMS28NDC Stratix 5410 28 Port Managed Switch

193-ESM-IG-100A-C97 E300/E200 100 Amp Sensing Module

20-750-I1-C540D485 PowerFlex 750 Inverter Assembly Kit

2090-CPWM7DF-14AF07 MP-Series 7 m Length Power Cable

2098-DSD-HV100-DN Ultra 3000 Servo Drive

GA646PME010 GlobalCare Assist for PCM Machine Edition Version 10 User

GP-0602NT-F4SB GagePort LVDT NT (Full Bridge for Solartron) - Sales BOM.

IC5002TBX0010 PanelPC 12 inch Perbance Unit with Windows XP

IC647HSTAE150KM Alarm and Events Option for Historian - Standard Server 150000 Points (M4 Key)

IC647SMM001 Scheduler Material (BOM) Module

IC693MDL731LT 12/24 Vdc Output, 2 Amp, Negative Logic (8 Points) (LT)

IC756HDV001J-97 DV Development - HP/UX Op Sys Addt'l User, Japanese, Version 9.7

MSI-SDK-25 SDK Connections 25 Pack

PLC-5/1771 System 1771-IG TTL INPUT MODULE

Distributed I/O 1791D-0B16P DNET 24 VDC COMPACTBLACK I/O, 16 OUT SOURCE, BASE

Communications 1784-KTX ISA BUS PC CARD W/DH+, DH485 & RIO

Operator Interface 2706-P42C INVIEWW MESSAGE DISPLAY. 1 OR 2 LINE

Support 9305-RSVADSFRR SUPT REINSTATEMENT CONTRACT FOR 9305RSVADSFR

Support 9515-RSEOL040S SUPT RENEWAL CONTRACT FOR 9515RSEOL040ENE

EtherNet/IP Products 2711-K6C20 PV600 COLOR KEY, ENET & RS232 PRINT

RSI Software Products 9301-2SE3403ITE RSVIEW32 RUNTIME 32K WITH RSLINX (ITALIAN)

RSI Software Products 9356-PRO2100U1R UPGRADE: OUT-SUPT: RSSQL STD.150 TO PROF.150 TAG

Motion Control 1326AB-B530E-M2L MOTOR,SERVO,460V,18.0NM,3000RPM,MULTI,IP67

4161-5-24 BCD To 7 SEG Display . 5 Digit, 24VDC. Dust Seal

HMI-CCT-202 BACKLIGHT TUBE 5"

IC693CMM302LT Communication Module, Genius (1 Kbyte) GCM+ (no datagram support) (LT)

QSL21100C2P QUICKSTART KIT 12.1" TFT

TRM-21006673 4 point screw terminal AC power connector for 7.2 amp 460 VAC S2K

20BC8P7A3NYNACC1 PowerFlex 700 AC Drive 8.7 A 4 kW 20B

20F1ANF142JA0NNNNN PowerFlex 753 AC Packaged Drive

22B-E4P2C104 PowerFlex 40 2.2 kW (3 Hp) AC Drive

140AMM09000 Quantum 模擬量混合模塊, 4通道輸入, 2通道輸出

284E-FVD7P6Z-25-RRN-3-DB-SB-EMI-OC EtherNet Variable Frequency Drive

E2E-X10Y1 10mm,電感式,二線,常開(kāi) 300mA 電源:24-240VAC圓M30

1492-SPM1C250-N MCB Supplementary Protector 25 A

通用型變頻器 6SE6 430-2UD41-1FB0 110 KW,326 x 1400 x 356

電機(jī)啟動(dòng)器 3VU13402ME00

150-C201NBR SMC-3 201A Smart Motor Controller

1608P-BP110A480V3 ProDySC 110 Amp Bypass

1770-CD3 Data Highway 300-300 ft Length Cable

193-DNCT-BZ1 DeviceNet Door Mount Bezel Kit

194R-S1 194R Standard Length Operating Shaft

2090-CPBM7E7-08AF20 20 m Length SpeedTec Extension Cable

2090-XXTPMP-16S90 MP-Series 90 m Length Power Cable

CP5B-0WEB-0070-AZ Shielded motor power cable for B12is motor(straight connector). 7 meters

GF-965012 Connecting FlashCable to Mitutoyo Indicator (543-11x/543-13x/543-14x/5 43-18x/543-17x).

IC200UEX010-24 Qty of 24, 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240 VAC Power Supply (includes IC200CBL501)

IC647ADC050 PA Dashboard Client 50 Pak