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A20B-3300-0360

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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1497B-A6-M14-0-N 1497B 250VA 240X480-120

1606-XLS80E Power Supply XLS 80 W Power Supply

1769-IM12 CompactLogix 12 Pt 240VAC D/I Module

189-AST1 MCB Accessory Shunt Trip Module

194R-HM4E-L 194R 600-1250 A Operating Handle

2090-CPBM7DF-14AA09 MP-Series 9m Standard Cable

2090-XXNPMP-8S07 MP-Series 7 m Length Power Cable

CBL-3C-L1D-FLY-20 S2K flying lead feedback cable for special for 3rd party motors with hall commutating encoders. 20 feet

GF-0520R Connecting FlashCable to Brown & Sharpe Micro Hite (10/11).

IC200TBX364 Tool box, Micro 64, operator interface and software. Includes (IC200UDR164) 24VDC In/Relay Out, AC Power Supply, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with VersaMax DataPanel DP45 with Proficy Logic Developer programming soft

IC646TBSPMSS010 Smart Process Monitoring SPC+ server 10 KPIs

IC647NTN000 CIMPLICITY HMI SIEMENS TI Communications

IC693ACC400 Expanded battery backup for Series 90-30 CPUs. Quantity 1. 8.5 Amp hour battery for Series 90-30 CPU311, 313, 323 and CPU36x type only. Not compatible with Series 90-30 CPU37x CPUs. The battery mounts on power supply and extends the depth of the s

IC752CBT053RR Datapanel 320T CB (Color Base) with Advanced software: 320x240 1/4 VGA Passive Color with 80386SX/40 PC processor. Analog touch screen with text, bitmaps, bar graphs, real time clock. With Real Time Trends & H ost Communications.

IC800VMCP3050 Power cable for 3 kW VersaMotion servo motors- 5 meter

SLC/1746 System 1746-NIO4I (2) ANALOG INPUT, (2) ANALOG CURRENT OUTPUT

Industrial Computers 6189V-CPUSTD3 STANDARD SBC (W/CPU AND COOLER) (700R)

Application-specific products 1403-CF020 20 M F LINK FOR POWERMONITOR

Operator Interface 2711-K6C10 PV600 COLOR KEY, DNET & RS232 PRINT

Support 9301-2SE2400PTS SUPT RENEWAL CONTRACT FOR 93012SE2400PT

Support 9323-ATUNER SUPT REINSTATEMENT CONTRACT FOR 9323ATUNEENE

DeviceNet Products 1734-OB4E 24V DC 4 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE3100JPE RSVIEW32 RUNTIME 150 (JAPANESE)

RSI Software Products 9358-BNTK30U2R UPGRADE: OUT-SUPT: RSBATCH BACK-UP KEY 10 TO 30

Motion Control MPL-B420P-MJ24AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,460V,BRK,6.8KG

Motion Control 2090-UXBB-DM15 BREAKOUT BOARD, CN2, ULTRAX000 DRIVE MOUNTED

GFK-0776 SS-90 Digital 100/200 Brushless Servo Amplifier Instruction Manual

IC646MDA150 View 150 Tag Runtime & Development System

MSC-V-C 0-10 V in / 4-20 mA out

PSPC-MONITOR10/E Prof Shop Floor SPC Monitor 10 User eSig

20BC022A0AYNACC0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC015AA0NNNNN PowerFlex 753 AC Packaged Drive

2198-P141 Kinetix 5700 DC Bus Supply

2711P-RCKS PanelView Plus 7 Accessory

280D-F12B-10B-CR ArmorStart Direct Online Starter

CQM1-AD041 模入單元. 4路 ±10V/0-10V/1-5V/4-20mA

1492-N8 TERM BLCK Adhesive Label

安裝導(dǎo)軌 6ES7390-1AB60-0AA0 安裝導(dǎo)軌，160 mm

變送器 3RS18001HW00

TIA 博途 WinCC 選件 6AV2107-0LK00-0BB0 SIMATIC WinCC DataMonitor for Runtime Professional 50 Clients

1585J-M8PBJM-10 RJ45 Ethernet Media

1760-L12DWD Pico 12 Point Controller

188-K2C160 Miniature Circuit Breaker 16 A

194L-A25-1754 25 A 194L Load Switch

2090-CNSRPRS-AA09 Kinetix 6000M Network Cable

2090-XB120-06 107 Amp 6 Ohm Resistive Brake Module

BC647MRA150 View Runtime 150 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFSTRNUNLMT GCC iFIX Std HMI Unlmt Run

IC200CPU005 CPU 128K user configurable user memory, 0.8MSEC/K Boolean one RS232 and one RS485 serial ports

IC646NCL000 Action Calender

IC647IFSTRN00900K iFIX Standard HMI 900 I/O Runtime (M1 Kit Part)

IC670MDD441 Mixed Discrete Module, 24VDC 10 in/6 out w/ESCP