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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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SLC/1746 System 1746-RL58 REPLACEMENT OCTAL LABEL KIT FOR CTLG # 1746-IC16

Distributed I/O 1734-TB3Q10 TEN 12-POSITION IP20 SCREW TERMINAL BASES

Application-specific products 9307-EMCHTENE RSENERGYMETRIX CHARTPLUS

Operator Interface 2711-NDRC DH+/RIO CONNECTOR FOR PV1200/1400E/1000E

Support 9302-MGXR SUPT REINSTATEMENT CONTRACT FOR 9302MGX

Support 9510-PBENR SUPT REINSTATEMENT CONTRACT FOR 9510PBEN

DeviceNet Products 1784-PCD1 DEVICENET PCMCIA CABLE (PC CARD CONNECTOR TO

RSI Software Products 9301-2SE3350U2 UPGRADE: IN-SUPT: RSVIEW32 RUNTIME 300 TO 5000

RSI Software Products 9310-CPSAUTOENE RSTESTSTAND ENTERPRISE AUTOMOTIVE

Motion Control MPL-SSN-A9B9 KIT,SHAFT SEAL,FOR MPL-A9XX AND MPL-B9XX MTRS

Silver Series 1747-PT1 HAND HELD TERMINAL - INCLUDES 6 FT/1.8 M CABLE

HE693DNT250 DeviceNet Scanner (master) module for Series 90-30.

IC648CTL970 CIMPLICITY Control 90-70 Annual Maintenance

QPI2D100L2P QUICKPANEL MONO 10.5" LCD

ST-4214 STXi analog output module 4 Channels, 4~20mA, 12bit

20BC170A0ANNANA0 PowerFlex 700 AC Drive 20B

20F1AGC205JA0NNNNN PowerFlex 753 AC Packaged Drive

22A-D8P7N104 PowerFlex 4 3.7 kW (5 Hp) AC Drive

140DAI45300C Quantum 開(kāi)關(guān)量AC輸入,32點(diǎn),48VAC,8點(diǎn)成組隔離,CC

284D-FVD2P3B-10-CR-SB DeviceNet Variable Frequency Drive

WS02-OPCC1-E OPC SERVER

1492-RXIM24-8R BUL.1667-PANELCONNECT INP

WinCC 上位監(jiān)控軟件 6AV6381-1BM06-0DV0 "WinCC?V6.0 RC?128?（128 個(gè)外部變量）"

變送器 3RS17222ET00

1497B-A1-M13-0-N 50VA 120x240-24V 60Hz CPT

1606-XLRED40 1606 Power Supply

1768-PB3 CompactLogix L4x DC In Power Supply

188-K4D010 Miniature Circuit Breaker 1 A

194R-B32-1753 BS88 194R Disconnect Switch

2090-CPBM7DF-10AF15 MP-Series 15m Continuous-Flex Cable

2090-XXNPMP-14S09 MP-Series 9 m Length Power Cable

CBL-13-MP-30 Power cable for MTR-1220 or MTR-1235 or MTR-1300 or MTR-1400 or MTR-1N series stepping motors. 30 feet

GC647WFL025 Proficy GlobalCare Complete for Proficy Workflow - 25 User License

IC200SET001 Ethernet to Serial Interface

IC646TBLSS40K Proficy Troubleshooter for Inbligent Historian for Hist 40000 Points

IC647NMB000 MODBUS PLUS OPC Server

IC693ACC306 EPROM Chips (qty 4)

IC698RMX016CA RX7I REDUNDANT MEMORY EXCHANGE 16MB CONFORMAL COATED

IC800VMCB2100 Motor power and brake power cable for 2 kW VersaMotion servo motor- 10 meter

SLC/1746 System 1746-OA16 AC OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-14SXPH VERSAVIEW NON-DISPLAY COMPUTER

Application-specific products 6556-SCBK2DC SLC FIXED CLUTCH/BRAKE KIT DC I/O

Operator Interface 2711-T5A5L1 PV550 MONO TOUCH, RS232 (DH485)

Support 9301-2SE2300ESR SUPT REINSTATEMENT CONTRACT FOR 93012SE2300ES

Support 9307-64MGDBCS SUPT RENEWAL CONTRACT FOR 930764MGDBCENE

DeviceNet Products 1732D-OB8EM12 DEVICENET 24VDC 8 0.5A OUTPUT W/M12

RSI Software Products 9301-2SE250ITU4R RSVIEW32 WORKS 150-100K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-BNT03UB1R UPGRADE: OUT-SUPT: RSBATCH 03 UNITS TO BUNDLE

Motion Control MPL-B310P-SK22AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V

Motion Control 2090-XXNPY-16S09 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,9M

GFK-0256 MegaBasic Language Reference and Programmer's Guide

IC641VPH700 VersaPro Professional Edition - Windows Programming Software with Programming Cable for Series 90-70, Series 90-30, and VersaMax PLCs

IMC-316X-X-D IMC-D Series Servo Motor Controller, 6 Amp

PSPC-DC25-220 Prof Shop Floor SPC DC 25 User 220v

20BC011A0AYYANC0 PowerFlex 700 AC Drive 20B

20DM325N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H070-AD-T K5500 FR3 AC,DC Bus Connector

2711P-RAK12E PanelView Plus Accessory

280-PWRM35G-M2 ArmorStart Three-Phase Power Media

CQM1H-ABB21 絕對(duì)值編碼器 2點(diǎn)

1492-MUA2B-A7-A10 1772 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1AH02-0AE0 CP340，標(biāo)準(zhǔn)串行通訊模塊，RS232C 接口，最高19.2kbit/s,9 針 Sub-D 接口

行程開(kāi)關(guān) 3SE53220SH21

TIA 博途 WinCC 選件 6AV2107-0CR00-0BB0 SIMATIC WinCC Sm@rtServer for SIMATIC Basic Panels

1585J-M8HB-2 RJ45 Ethernet Media

1756-SYNCH ControlLogix SynchLink Comms Module

188-K1D320-N Miniature Circuit Breaker 32 A

194E-Y32M-1753-6N 32 A 194E Load switch

2090-CFBM7E7-CEAF12 Kinetix 12m Extension Cable