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現(xiàn)代航空發(fā)動機正朝著高溫、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，進而干擾控制系統(tǒng)使發(fā)動機性能下降［2］。因此，提高傳感器的可靠性對發(fā)動機安全、可靠工作極為重要。通過對傳感器故障件的科學(xué)診斷，探索其失效機理，將有利于傳感器的迭代設(shè)計，進而不斷提升可靠性。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，僅適用于對傳感器的金屬結(jié)構(gòu)進行觀察，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)動機數(shù)控系統(tǒng)的高壓壓氣機進口總溫傳感器的故障現(xiàn)象，利用工業(yè) CT 技術(shù)對其進行了無損檢測，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行了分析，采取了相應(yīng)的改進措施。最后通過試驗驗證了改進措施的有效性，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)動機數(shù)控系統(tǒng)的高壓壓氣機進口總溫傳感器( 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，無法對傳感器進行結(jié)構(gòu)和工藝上的改進，嚴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，細節(jié)分辨能力可達 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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Industrial Computers 6186-M17ALTR VERSAVIEW 17 INCH MONITOR, RESISTIVE TOUCH SCREEN

Application-specific products 1404-M405B-ENT 1404-M4 ETHERNET PM3000

Operator Interface 2711-T6C5L1 PV600 COLOR TOUCH, RS232 (DH485)

Support 9301-2SE3100JPS SUPT RENEWAL CONTRACT FOR 93012SE3100JP

Support 9380-RSBARR SUPT REINSTATEMENT CONTRACT FOR 9380RSBAR

DeviceNet Products 1734-TBSQ10 10 MODULES BASES W/ REMOVABLE IEC SPRING TERMINALS

RSI Software Products 9301-2SE3200U1R RSVIEW RUNTIME 150 TO 300 UPGRADE:OUT-OF-SUPPORT

RSI Software Products 9358-BPCNT60ENE RSBATCH PC-BASED PHASES 60 UNITS

Motion Control MPL-B4520P-RK24AA MOTOR,SERVO,6.1 NM,5000RPM,RSLVR,460V,BRK

Motion Control 2090-SCVG100-0 SERCOS FBR CABL,CONN,STNDRD PVC JKT,GLASS,100.0M

GFK-2210 PowerCube with Pulse & Direction Interface, Users Manual

IC646MGRS03 Electronic Signature option for a 3 users Procify Change Management system.

MTR-1235-E-D-E-0 Stepping Motor Nema23, Series Wdg, Encoder

QPICGAE0000 10.4 inch Color TFT/ GE Fanuc/ Ethernet/ CF Card/ 110 VAC

PXIe-5122

147-000047-00

Kontron 18030-0000-17-2

ASC-29320LPE

291300A 291300B

IAC-H669C

1492-PD3C2127 760 A Power Distribution Block

中央處理單元 6ES7414-3XJ04-0AB0 CPU414-3，1.4MB，60ns，電源 24VDC，MPI/PROFIBUS-DP 主站接口，PROFIBUS-DP 主站接口

變送器 3RS17061FW00

TIA 博途數(shù)字化選件 6ES7823-1EA00-0YL5 TIA Portal Teamcenter Gateway SUS

1585J-M8TBJM-2 RJ45 Ethernet Media

1761-CBL-AH02 MicroLogix Cable

188-K3B130-N Miniature Circuit Breaker 13 A

194L-E16-1753-6N 16 A 194L Load Switch

2090-CPBM4DF-16AF09 MP-Series 9m Length Cable

2090-XXNFMF-S09 Kinetix Drives 9m Standard Cable

BC647OEM0410B OEM Edge Program Add't Key - Historian