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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，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，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，容易造成故障點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，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，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。最后通過試驗驗證了改進(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，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，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工業(yè) CT 系統(tǒng)。該系統(tǒng)具備180 kV 微焦點定向式 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。

試驗時，利用微焦點錐束 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 X 射線源采用了低功率以獲得更小的焦點尺寸，調(diào)節(jié)射線源至故障件的距離以實現(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，以及在焊點根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個斷點。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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20L-GH30-A2 Hose Kit,(2)30 Ft X 1Inin,W/ Fit,1In Elb

25C-RCTB PowerFlex 527 Removable Terminal Block

280-PWRM22C-M10 ArmorStart Three-Phase Power Media

FX2N-48MT 主機(jī)24入/24出?晶體管輸出

1492-M6X12 IEC 6 x 12 mm Marker Card

1494R-N1 Lug Kit

軟啟動器 3RW44466BC46

ET 200SP 6ES7193-6BP20-0BF0 基座單元 BU20-P8+A4+0B ，類型F0，直插式端子，帶4個AUX端子，20mm寬

1585D-M4TBJM-3 Micro D-Code, QD Style Ethernet Media

1756-HYD02 ControlLogix Hydraulic Servo Module

1794-PS3 Flex Power Supply

194E-DA20E-P11 194E Load switch

2090-CDNFDMP-S15 MP-Series 15 m Length Feedback Cable

2090-K2CK-COMBO Kinetix 2000 Feedback I/O Connector Kit

AD641ECL720 ECLiPS Programming Software for the Series 90-70 CPU's, Serial, with O nTOP

GC646PME005 GlobalCare Complete for PCM Machine Edition Version 5 User

HE800ACC119 Cage-clamp (screw) style I/O plug, 19-terminal. (Qty 10)

IC640HWC306 LM 90-30/20/Micro DOS Serial Sw w/Conv & Cables, CD-Docs.

IC647HSTSSEO1KM eSignature Option for Historian - Standard Server 1000 Points (M4 Key)

IC660BLR100 Cover w/Label for IC660BBR100

IC695CPE305 CPE305 single slot CPU, 1.1Ghz processor,5 Meg user memory, 1 RS-232 port (IC693CBL316 cable), 1 Ethernet port (SRTP Programmer support only) and a USB master port upload/download only. Ships with Energy PAC IC695ACC400).

IC756WET200E-23 Custom Datasource Toolkit, English, Version 2.3

CompactLogix System D1769-UM005AENP COMPACT I/O TRD/RESISTANCE INPUT MODULE

PLC-5/1771 System D1771-6.5.120 TEMPERATURE CONTROL MODULE USER MANU SERIES B

Process Control 1757-PIM PULSE INPUT MODULE

Operator Interface 2711P-B7C6D2 PV PLUS 700, KEY/TOUCH, RIO/DH, DC PS, EXT MEM

Support 6556-SABR SUPPORT REINSTATEMENT CONTRACT FOR 6556-SAB

Support 9358-PLTMCLTS SUPT RENEWAL CONTRACT FOR 9358PLTMCLTENE

Support F1785-KA5SERA FIRMWARE UPGRADE FOR 1785-KA5 COMMUNICATION MODULE

RSI Software Products 9301-2SE2200ZHE RSVIEW32 WORKS 300 (CHINESE)

RSI Software Products 9701-VWSB000JPU3 RSV SE STATION 250 - UNLTD DISP UPGRADE (JAPANESE)

RSI Software Products 9399-EDS2UG RSWIRE SYSTEM USER'S MANUAL

Motion Control 2098-DSD-010-DN DRIVE, 5A/15A, ULTRA3000 W/DEVICENET

BC5002TBX0000 12" Bundled Intelligence Industrial Computer with WIN XP Performance Series

IC300CBF010 FOX Fiber Cable Pair, 10.0M

IC752DVT160 VT100 firmware on DataPanel 160 allows DataPanel to be used as terminal includes graphic support

MTR-3S43-H-R-0-E-SRR Servo Motor with Seal

ZA06B-6089-H711 External regeneration resistor with fan rated 8 ohm 800 Watt for Alpha SVU1-130 amplifier

20BE9P0A0AYNAND0 PowerFlex 700 AC Drive 9 A 7.5 Hp 20B

20G14TC750JN0NNNNN PowerFlex 755 AC Packaged Drive

25-RF8P0-BL PowerFlex 520 8.0A 600V EMC Filter Kit

2711P-T10C21D8S-B PanelView Plus 7 Standard 1000 Brandless

FRN 5 5P11S-4CX 8 5 KVA 112A 55KW 3相AC380V/50Hz/60Hz

1492-JD3FB 2.5 square mm Double Level Fuse Block

1492-W3-Y IEC Term Blck 8x47.6x41mm Screw

軟啟動器 3RW40756BB45

安全 CPU 模塊 6ES7 516-3FN01-0AB0 SIMATIC S7-1500F，CPU 1516F-3 PN/DP，中央處理單元，帶有：1.5 MB 工作存儲區(qū)，5MB 數(shù)據(jù)存儲區(qū)

156-B25AB2 25 A Contactor

1746-HSCE SLC High Speed Module

1786-RPFRL CNet Fiber Ring Long Distance Repeater