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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(diǎn)，容易造成故障點(diǎn)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(diǎn)，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(diǎn)，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(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(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手段，始終未能準(zhǔn)確地定位故障點(diǎn)，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(yàn)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(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(yàn)時，利用微焦點(diǎn)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(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(diǎn)，以及在焊點(diǎn)根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個斷點(diǎn)。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(diǎn)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(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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IC754PCMCIA001 PCMCIA Interface Adaptor

KIT-GFS-365-CN Proficy HMI_SCADA CIMP & iFIX Wkshp Kit

SLC/1746 System D1747-RM001CENP SLC 500 INSTRUCTION SET REFERENCE MANUAL

Distributed I/O 1734D-IB16S 24 VDC 16 IN, DNET COMMS, SPRING

Application-specific products 1803-EEM01 EEM, 8 ANALOG, 4 TO 20 MA

Operator Interface 2711-T10G1 PV1000 GRAYSCALE TOUCH, RIO & RS232 PRINT

Support 9301-2SE3500ITR SUPT REINSTATEMENT CONTRACT FOR 93012SE3500IT

Support 9381-PA500KENS SUPPORT RENEWAL CONTRACT FOR 9381PA500KEN

DeviceNet Products 1790D-T8BV8V DNET LDX 24VDC,8 UNIV IN/8 SINK OUT BASE, TERM BLK

RSI Software Products 9301-2SE330ESU2R RSVIEW32 RUNTIME 150-1500 UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-PBEBNT60ENE RSBATCH NT & EPROCEDURE BNDLE PROCESLGIX 60 UNITS

Motion Control MPL-B580J-MK22AA MOTOR,SERVO,34.0NM,3800RPM,MULTI,460V,32MM SHAFT

Motion Control 2090-UXLF-370 AC LINE FILTER,ULTRA,70 AMPS,3 PHASE

GQSI31200E2P QUICKSTART KIT 9" EL GE LABEL

IC646NHD000 Historical Data Analyzer

MTR-3T55-H-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

ST-1804 STXi b module 4 points, 110V AC (AC 85V ~ 132V)

20BC085A0AYNACD1 PowerFlex 700 AC Drive 85 A 45 kW 20B

20F11RD014AA0NNNNN PowerFlex 753 AC Packaged Drive

22A-A3P6N103 PowerFlex 4- 0.75 kW (1 HP) AC Drive

140CHS41020 Quantum Quantum經(jīng)濟(jì)性熱備包,140CPU11303

284-FAN ArmorStart Spare Parts

C2OOH-TS101 溫度檢測,鉑電阻信號（Pt） 4路

1492-RCDA4B40S Residual Current Device 40 A

同步光纜 6ES7960-1AA04-5BA0 同步光纜 2m

變送器 3RS10 42-1GW70

1497-H-BASX-0-N Control Circuit Transber

1606-XLE120EN Power Supply XLE 120 W Power Supply

1762-RPLDR2 MicroLogix Replacement Part

188-K3D130 Miniature Circuit Breaker 13 A

194L-HE4A-225 ACTUATOR HANDLE FOR LOAD SWITCH

2090-CPBM7DF-08AA07 MP-Series 7m Power and Brake Cable

2090-XXNPMF-14S09 Kinetix Drives 9m Standard Cable

BC647TPR915 CIMPLICITY HMI ProServer 1500 I/O Runtime System with Proficy GlobalCare

GC647PSC000 "Global Care###### CIMPLICITY#Proficy####, 5000###I/O"

IC200MDL750CA Conbal Coated Output 12/24VDC POS LOGIC 0.5A per point (2 groups of 16) 32 points

IC646PME001 Proficy Change Management for ME 1 User

IC647MTLC MTL:Mettler Weighing Terminals

IC684TROLI603 CIMPLICITY HMI Plant Edition Online Course -Module 3

IC697VAL304 Discontinued future replacement with Embedded VME-6550. Contact GE IP Embedded for details.

IC800SSI228RP2RR 28A, 230V, Profibus S2K Servo Controller for MTR Series Motors

SLC/1746 System 1747-L553 SLC 5/05 CONTROLLER

Industrial Computers 6181P-12TP2KHDC VERSAVIEW INTEGRATED DISPLAY COMPUTER 12-INCH

Application-specific products 9358-PBBK10ENE RSBIZWARE BATCH FOR PLX BACK-UP KEY 10 UNITS

Operator Interface 2711-K5A10L3 PV550 MONOCHROME KEY, DNET & RS232 PRINT

Support 9306-4EXP02R SUPT REINSTATEMENT CONTRACT FOR 93064EXP02ENE

Support 9393-RSTCLXS SUPT RENEWAL CONTRACT FOR 9393RSTCLX, 9393RSTPCLX

ControlNet Products 2711-K10G15L1 PV1000 GRAYSCALE KEY, CNET & RS232 PRINT

RSI Software Products 9301-2SE2500PTU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (PT)

RSI Software Products 9358-BEPB30U1R UPGRADE: OUT-SUPT: RSBW BATCH & EPROCEDURE 03 TO30

Motion Control MPL-A4540C-SK22AA SOTOR,SERVO,10.2NM,1500RPM,SINGL,230V,9.5KG

Motion Control 2090-XXNFY-S03 CABLE,NON-FLEX,MOTOR FEEDBACK,Y,3M

CBL-T7-MP-30 Power Cable, MTR-3T1x & MTR-3T2x Series Servo Motors, 30 Ft.

IC641PCC124 Logic Engine (runtime) w/o GUI - 512 Points

IC800SSD228RS1 28A, 230V, S2K Servo Drive for MTR Series Motors

PR-PAT-FS01 Proficy PAT - Driver For Foss Near Infrared Systems Near-Ir Spectrometers

20BB-DB1-2 PowerFlex 700 Resistor Kit

20DD820A0ENNBNANE PowerFlex 700S AC Drive 820 A 700 Hp 20D