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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(xiàn)機(jī)，僅適用于對(duì)傳感器的金屬結(jié)構(gòu)進(jìn)行觀(guān)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(guān)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(guān)、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(chēng)“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(xiàn)、墊塊等組成，其中薄膜鉑電阻的引線(xiàn)與轉(zhuǎn)接導(dǎo)線(xiàn)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(xiàn)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(xiàn)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(xiàn)源采用了低功率以獲得更小的焦點(diǎn)尺寸，調(diào)節(jié)射線(xiàn)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(xiàn)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(xiàn)、導(dǎo)線(xiàn)) 、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(xiàn)與轉(zhuǎn)接導(dǎo)線(xiàn)的焊點(diǎn)，以及在焊點(diǎn)根部的多股轉(zhuǎn)接導(dǎo)線(xiàn)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(guān)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(xiàn)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(xiàn)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(xiàn)比較松散，部分小股線(xiàn)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(xiàn)圈出的區(qū)域) ，說(shuō)明轉(zhuǎn)接導(dǎo)線(xiàn)周邊的灌膠不充分，有氣泡、空腔存在。
 

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Operator Interface 2711P-RGT7 PV PLUS/VVCE PROTECTIVE ANTIGLARE OVERLAYS QTY 3

Support 9355-WABOEMFRR SUPT REINSTATEMENT CONTRACT FOR 9355WABOEMFR

Support 9354-SS105S 9354-SS105 SOFTWARE SUPPORT CONTRACT RENEWAL

ControlNet Products 1734-IA2 120 VAC 2 CHANNEL INPUT MODULE

RSI Software Products 9301-2SE2400PTU3 RSVIEW32 WORKS 150-32K UPGRADE IN-SUPT (PT)

RSI Software Products 9357-ANETMDAD3E RSNETWORX MD FOR CNET,DNET,ENET ADD-ON

Motion Control MPL-A330P-MK22AA MOTOR,SERVO,4.18 NM,5000RPM,MULTI,230V,5.0KG

Motion Control 2090-UXNBMP-18S15 CABLE,ULTRA,NON-FLEX,MOTOR BRAKE,MP 15 MTR.

CBL-136 Cable. Mitsubishi A Series Prog. Port (RS-422)

IC600RR551RR RPU Rack With Power Supply, 115-230Vac

IC800SKCEZ050 Encoder Cable, S2K to 200-750W S-Series Servo Motors, 5 Meters

OC647IFESGSR00150C iFIX Optn: ESig & ERec 150 I/O Server (M1Component Part)

20AD052F3AYNANC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A3EYYAEASE PowerFlex 700S AC Drive 20D

20P21AD010RA0NNN PowerFlex 10 A DC Drive

2711-CBL-PM10 PanelView 300 10m Operate and Prog Cable

280-PWRM22E-M8 ArmorStart Three-Phase Power Media

FX2N-4AD-TC 4通道熱電耦模擬量輸入模塊

1492-M8X5 IEC 8 x 5 mm Marker Card

1494U-C314 1494U 30A-100A 4' Cable Mechanism

軟啟動(dòng)器 3RW44532BC36

SIMATIC STEP 7 V14 6ES7822-1AA04-0YA5 SIMATIC STEP 7 專(zhuān)業(yè)版 V14 浮動(dòng)授權(quán)

1585D-M4UBDE-80 Micro D-Code, QD Style Ethernet Media

1756-IC16 ControlLogix 16 Pt 48V DC D/I Module

1794-TB62DS Flex Terminal Base

194E-E16-1756 16 A 194E Load switch

2090-CFBM4DF-CDAF05 MP-Series 5m Feedback Cable

2090-KFBM7-CAAA MP-Series Feedback Connector Kit

BC5005TAX0000 15 Inch Inbligence Industrial Computer - Bundled - Standard Series - w/ Windows XP

GC646TJT000 Proficy GlobalCare Complete for HMI Tracker Server - Inb

HMI-BEZ-202 Stainless Steel Bezel: 9 inch Mono (QPI2xxxxE2P)/ NEMA 4X

IC641CFG100 VersaPro Remote I/O Manager

IC647I3EM I3E:IEEE 488.2

IC660CBB903RR Series Six Bus Controller without Diagnostics, Ph B

IC695FTB1B032 Fiber terminal Block kit includes the IC695FTB001 base plus two IC694TBS032 high density box style screw terminal blocks

IC756WRE024J-12 DV-Centro Runtime WinNT Jap v1.2.1

FlexLogix System 1794-ACNR15 REDUNDANT MEDIA ADAPTER FOR CONTROLNET

PLC-5/1771 System D1771-6.5.77 THERMOCOUPLE/MILLIVOLT INPUT MODULE(1771-IXE/B)MNL

Process Control 1757-PLXNW OPEN DATA ACCESS - 10 USER

Operator Interface 2711P-T7C15B2 PV PLUS 700, TOUCH, CNET, AC PS, EXT MEM

Support 6626-PLPR 6626-PLP SOFTWARE SUPPORT REINSTATEMENT

Support 8520-ODSS SUPT RENEWAL CONTRACT FOR 8520ODS

Support F1785-L20C15SERE FIRMWARE UPGRADE FOR 1785-L20C15 PLC5 PROCESSOR MO

RSI Software Products 9301-2SE220JPU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (JP)

RSI Software Products 9701-VWSB100ENU1 RSVIEW SE STATION 25 - 100 DISPLAY UPGRADE

RSI Software Products 9399-HDWAREREFPT HARDWARE INTERFACE CONFIG. USER GUIDE (PORTUGUESE)

Motion Control 2098-DSD-HV150-DN HIGH VOLTAGE DRIVE, 34A/68A, ULTRA3000 W/DNET

BC646CSCEMK ControlStation CE Development Software with 1 year SAFE

IC300DIQ627 8 AC Input (120 VAC) , 8 AC Output (250 VAC max, 2A)

IC752MNH899 Monitor -- 18" flat panel LCD active matrix monitor. No touch.

MTR-3S46-H-R-0-E-SRR Servo Motor with Seal

ZA06B-6110-K210 AHVi Amplifier CXA2A/B Connector

20BP205A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TF500JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B032N104 PowerFlex 523 7.5kW (10Hp) AC Drive

2711P-T12W22A9P PanelView Plus 7 Graphic Terminal

OPC-G11S-DEV(通訊卡)

1492-JG16 16 square mm Ground Terminal Block

1492-WFB424 IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44223BC44

備品備件 6ES7 591-1AA00-0AA0 CPU 顯示面板：適用 CPU 1511/1513

1585D-M4DC-H Ethernet Media

1756-L72S Logix 5572S Automation Controller 4M/2M

188-K3D020-N Miniature Circuit Breaker 2 A

193-T1DC60 45-60 A IEC Bibllic Overload Relay

20-IP20DR-600 PowerFlex 700H/S Door Kit

2090-CSBM1DF-14AF07 Kinetix Cable Single DSL 2090-Series

20AC022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT915 Proficy GlobalCare Assist for CIMPLICITY HMI Server 1500 I/O Runtime System

GPA-602-F LVDT Expansion Unit (Full Bridge), includes G-0602 connecting cable.

IC600CM548RR 8K CMOS Logic Memory Module (for use in Model 600 or 6000)

IC647HSTCSEO1500KM eSignature Option for Historian - Enterprise Corporate Server 1,500,000 Points (M4 Key)

IC647WFL001 Proficy Workflow - 1 User License

IC694ACC300 Input simulator module, 16 points.

IC756RDV001K-98 DV Development - Irix Op Sys Addt'l User, Korean, Version 9.8

MicroLogix 1200 System 1762-L40BXB MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-LC4B LOOP CONTROLLER W/RTD OPTION,240V AC SUPPLY