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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診斷，探索其失效機理，將有利于傳感器的迭代設計，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 技術能清晰、直觀、準確地呈現(xiàn)被檢測物體內(nèi)部的結(jié)構( 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)領域有著廣泛的應用［3 ～ 7］。工業(yè) CT 的上述特點，使其成為傳感器故障無損、準確、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 技術對其進行了無損檢測，從而快速、準確地定位到故障點，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)接導線、墊塊等組成，其中薄膜鉑電阻的引線與轉(zhuǎn)接導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，始終未能準確地定位故障點，無法對傳感器進行結(jié)構和工藝上的改進，嚴重影響了傳感器的可靠性提升。


2 、CT 故障定位

2． 1 檢測設備與試驗條件

傳感器故障件檢測設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)接導線的焊點，以及在焊點根部的多股轉(zhuǎn)接導線上出現(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)接導線周邊的灌膠不充分，有氣泡、空腔存在。
 

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Motion Control MPL-B310P-SK24AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,460V,BRK

Motion Control 2090-XXNPY-16S12 CABLE,NON-FLEX,MOTOR POWER,Y,16 GAUGE,12M

GFK-0263 Logicmaster 90-70 Programming S/W User's Manual

IC641VPP700 VersaPro Professional Edition - Windows Programming Software for Series 90-70, Series 90-30, and VersaMax PLCs

MICROGUS Win95/NT Programming Software for Microgreyline

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

20BC011A0NYNANC0 PowerFlex 700 AC Drive 20B

20DM460N0ENNBNANE PowerFlex 700S AC Drive 20D

2198-H070-ADP-IN K5500 FR3 b connector set

2711P-RAK12S PanelView Plus Accessory

280-PWRM35G-M20 ArmorConnect 3-PH Power Media trnk cable

CQM1H-MAB21 模擬量I/O板 2點

1492-MUA3-A10-A13 1773 - 1756 Conversion Mounting Assembly

通訊處理器CP 6ES7 340-1BH02-0AE0 CP340，標準串行通訊模塊，20mA /TTY 接口，最高 19.2kbit/s,15 針 D 型接口

行程開關 3SE53220SJ21

TIA 博途 WinCC 選件 6AV2107-0FB00-0BB0 SIMATIC WinCC Redundancy for Runtime Professional

1585J-M8HB-5 RJ45 Ethernet Media

1756-TBCH ControlLogix 36 Pin Screw Terminal Block

188-K1D400 Miniature Circuit Breaker 40 A

194E-Y40-1753-6N 40 A 194E Load switch

2090-CFBM7E7-CEAF20 20 m Length SpeedTec Extension Cable

2090-UXNPAMP-10S30 MP-Series 30 m Length Power Cable

BC646VSCEMK Proficy Machine Edition View Standard with Global Care

GC647IFPLSR00900 GCC iFIX Plus SCADA 900 I/O Srv

IC200CBL635 Siemens S7-2000 9-pin, RS-485 Cable to DataPanel 45/65/85

IC646MPS101 Logic Developer PLC Standard with Programming Cable

IC647IFSTDV00075C iFIX Standard HMI 75 I/O Development (M1Component Part)

IC670ALG240RR Analog Input Current 16 Channel

IC697CPU781RR CPU, 16 MHz, 12K Discrete I/O, Expandable Memory

IC800PSHV030 PSM-30HVi 301 kW high voltage power supply kit for Alpha servos

ControlLogix/1756 System 1756-OV16E 10-30 VDC ELEC FUSED SINKING OUTPUT 16 PT (20 PIN)

Industrial Computers 6182H-10KRH4B VVCE 1000, KEYPAD, STD MEM, ENET, AC

Process Control 1757-FIMEXP080 FOUNDATION FIELDBUS FIM MODULE EXPANSION

Operator Interface 2711P-RDB15C PV PLUS 1500, KEY/TOUCH SCREEN DISPLAY MODULE

Support 9355-WABCENS SUPT RENEWAL CONTRACT FOR 9355WABCEN