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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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IC800VMCB2030 Motor power and brake power cable for 2 kW VersaMotion servo motor- 3 meter

SLC/1746 System 1746-IV32 DC INPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6155R-14PXPH VERSAVIEW NON-DISPLAY COMPUTER, 14 SLOT

Application-specific products 6556-SCBK SLC PROGRAMMABLE PRESS CONTROL KIT

Operator Interface 2711-T5A2L1 PV550 MONO TOUCH, DH485

Support 9301-2SE2300DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2300DE

Support 9307-10KMGDBPS SUPT RENEWAL CONTRACT FOR 930710KMGDBPENE

DeviceNet Products 1732D-IB8M12 DEVICENET 24VDC 8 INPUT W/M12

RSI Software Products 9301-2SE250ITU2R RSVIEW32 WORKS 1500-100K UPGRADE OUT-SUPT (IT)

RSI Software Products 9358-BNT03ENE RSBATCH 03 UNITS

Motion Control MPL-B310P-SJ22AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V,3.0KG

Motion Control 2090-XXNPY-16S05 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,5M

GFH-001 Servo Product Specification Guide (Alpha and Beta Series)

IC641SWP719 C Toolkit for Series 90-70 (Professional)

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

PSPC-DC10L Prof Shop Floor SPC DC 10 User

20BC011A0AYNAND0 PowerFlex 700 AC Drive 20B

20DM261N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H040-P-T K5500 FR1,2 control power con

2711P-RAAT7 PanelView Plus 7 Series Accessory

280-PWRM35G-M10 ArmorStart Three-Phase Power Media

CQM1H-CTB41 高速計(jì)數(shù)器板 4點(diǎn)3

1492-MS8X9 IEC 8 x 9 mm Marker Card

模擬量輸入/輸出模塊SM 6ES7 332-5HD01-0AB0 AO/4 通道，電壓、電流，光電隔離，20pin 前連接器

行程開(kāi)關(guān) 3SE53220SG23

運(yùn)行版軟件 6AV2105-4TT04-0AE0 SIMATIC WinCC Runtime 專業(yè)版 V14 Upgrade WinCC V7.0..V7.3 Runtime 262144 PowerTags ->WinCC Runtime 專業(yè)版 262144 PowerTags V14

1585J-M8FBJM-5 RJ45 Ethernet Media

1756-SPESMNRM L7SP Energy Storage Module-Non Remove

188-K1D250-N Miniature Circuit Breaker 25 A

194E-Y32M-1753-6G 32A 3P LOADSW. IN M/THREAD BOX

2090-CFBM7E7-CEAF09 9 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S03 MP-Series 3 m Length Power Cable

BC646TRT915 Server 1500 I/O Runtime System with Proficy GlobalCare

GC647IFPLSR00075 GCC iFIX Plus SCADA 75 I/O Srv

IC200CBL602 Cable expansion shielded 2M 2 connectors

IC646MPS005 Logic Developer PLC Standard 5 Pack

IC647IFSCTSSPRT03M iFIX TS SCADA Support on SCADA -3 Clients (M4 Part)

IC670ALG230 Analog Input, Current, 8 Channel, Grouped

IC697CPU772RR CPU, 12 MHz, 2K Discrete I/O, Expandable Memory, Floating Pt

IC800PCUBC10S050 Powercube flying lead interface cable configured for 1000 steps/revolution and power save enabled. 5 meters

ControlLogix/1756 System 1756-OB8EI 10-30 VDC ISOLATED ELEC FUSED OUTPUT 8PTS (36 PIN)

Industrial Computers 6182H-10KEH6D VVCE 1000, KEYPAD, EXT MEM, RIO/DH, DC

Process Control 1757-FIMEXP035 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RBT7 PV PLUS 700 TOUCH REPLACEMENT BEZEL

Support 9355-WAB1OEMENR SUPT REINSTATEMENT CONTRACT FOR 9355WAB1OEMEN

Support 9351-VSRTR SUPT REINSTATEMENT CONTRACT FOR 9351VSRT

ControlNet Products 1785-L40C15 PLC-5/40C FOR CONTROLNET PHASE 1.5

RSI Software Products 9301-2SE2400FRU1 RSVIEW32 WORKS 1500-32K UPGRADE IN-SUPT (FR)

RSI Software Products 9355-WABJBENE RSLINX OEM/RSJUNCTIONBOX BUNDLE

Motion Control MPL-A320H-SJ22AA MOTOR,SERVO,2.26 NM,3500RPM,SINGL,230V,4.0KG

Motion Control 2090-DAPC-D0903 CABLE, NON-FLEX, CN3 SERIAL COMMUNICATIONS, 03M

CBL-114-1 Cable. Allen Bradley PLC5 Channel 0 (RS-232)

IC5008TBW2000 Discontinued - Order a BC5008TBW0000 & Appropriate CIM PE License

IC800PCUBC02S050 PowerCube Flying Lead Interface Cable, 200 Steps/Rev & Power Save Enabled, 5 Meters

OC647IFESGCLNTSM iFIX Optn: ESig & ERec iClientTS (M4 Part)

20AD027A0AYNANC0 PowerFlex 70 AC Drive 27 A at 20 Hp 20A

20DC2P1A0NYNANANE PowerFlex 700S AC Drive 20D

20G1ANF212JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-E1P7N104 PowerFlex 527 0.75kW (1Hp) AC Drive

280-PWRM22B-M6 ArmorConnect 3-PH Power Media drop cable

FX2N-48MR-001 主機(jī)24入/24出?繼電器輸出

1492-M5X8C Connection Products

1494H-EF3H6 Heavy Duty Fusible Safety Switch

軟啟動(dòng)器 3RW44462BC46

ET 200SP 6ES7193-6BP40-0BA1 基座單元 BU15-P16+A0+12B/T，類型A1，直插式端子，帶2x5個(gè)附加端子，帶有溫度測(cè)量，15mm寬

1585D-M4TBJM-12 Micro D-Code, QD Style Ethernet Media

1756-ESMNSE ControlLogix Energy Storage Module

1794-OV16 Flex 16 Point Digital Output Module

194E-CA80E-PE-TN 194E Load switch