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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，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(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，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，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。最后通過試驗驗證了改進(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，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，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(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。

試驗時，利用微焦點錐束 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 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(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，以及在焊點根部的多股轉(zhuǎn)接導(dǎo)線上出現(xiàn)了一個斷點。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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運行版軟件 6AV2104-4BB04-0AE0 SIMATIC WinCC Runtime Advanced V14 Upgrade ： WinCC flexible 2008 Runtime 128 PowerTags -> WinCC Runtime Advanced 128 PowerTags V14

1585J-M4TBJM-15 RJ45 Ethernet Media

1756-OB16IEFS ControlLogix 16 Point Digital Output

188-K1B630 Miniature Circuit Breaker 63 A

194E-G3663 Abs Thermoplstc Encl 125 X 180 X 105 mm

2090-CFBM7DF-CDAF25 MP-Series 25m Feedback Cable

2090-UCSR-P900 Shunt Resistor

BC646OEM0200 OEM Edge - CIMPLICITY HMI Kit (Approval Required)

GC647DMC003 GC DataMart 3 Reporting Clients

IC200ALG230LT ANALOG INPUT 12 BIT VOLTAGE/CURRENT 4CH (LT)

IC646CSPWR-43 Proficy Cause+ Web Report User

IC647IFPLSR00300C iFIX Plus SCADA 300 I/O Server (M1Component Part)

IC660MLD022 Label for IC660BBD022 (Qty 100)

IC697BEM713 Bus Transmitter (Also Provides Parallel Programming Port)

IC800ABK001 Panel mounted encoder battery kit for Alpha HVi amplifiers

FlexLogix System 1794-STRT1PT FLEXLOGIX STARTER KIT PORTUGUESE

GuardPLC Systems D1753-UM001AENP GUARDPLC CONTROLLER SYSTEMS USER MANUAL

Process Control 1757-UPGSIFZF UPGRADE BAILEY INFI90 QUICKBUILDER INTERFACE

Operator Interface 2711P-B15C15D2 PV PLUS 1500, KEY/TOUCH, CNET, DC PS, EXT MEM

Support 9230-IOLINXSDKR SUPT REINSTATEMENT CONTRACT FOR 9230IOLINXSDK

Support 6300-DES 6300-DE SOFTWARE SUPPORT RENEWAL

Support F1785-V80BSERC FIRMWARE UPGRADE FOR 1785-V80B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2350PTU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (PT)

RSI Software Products 9701-VWSTPU1 RSVIEW STUDIO FOR ME TO RSVIEW STUDIO WITH PE

RSI Software Products 9399-WABOUGPT RSLINX OEM USER GUIDE (PORTUGUESE)

Motion Control 8720MC-HF-B 460VAC HARMONIC FILTER

BC646MRC300 Logic PC & View Runtime 300 I/O

IC300RCS071 16 DC Inputs (12/24vdc), 12 Positive Logic DC Outputs (5/12/24vdc, 0.5A with ESCP)

IC754VBI06MTD 6" Monochrome Quickpanel View Intermediate, Touch, 24VDC, Blank label

MTR-3T54-H-R-B-M-0RR Servo Motor Metric 24V Brake

20AC8P7A3AYYANC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC030A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ANC140JN0NNNNN PowerFlex 755 AC Packaged Drive

25B-E022N104 PowerFlex 525 15kW (20Hp) AC Drive

2715-T7CA PanelView 5500 6.5 in. Graphic Terminal

FR-A740-37K 54KVA 71A 37KW

1492-LDG3P IEC Term Blck 5.1x95x41mm Spr Clp

1494F-N20 Master Door Interlock Kit

軟啟動器 3RW44356BC35

ET 200SP 6ES7131-6BF00-0AA0 DI 8x24VDC 基本型， 基座單元類型 A0

1585D-E4TBDE-2 Micro D-Code, QD Style Ethernet Media

1753-HHT GuardPLC Handheld Terminal

1794-IB16D Flex 16 Point Digital Input Module

194E-AA20EX-6 194E Load switch

2080-LC20-20QBBR Micro820 20 I/O ENet/IP Controller (RTB)

2090-CSWM1DF-14AA25 Kinetix Cable Single DSL 2090-Series

20AC3P5A0AYNANC1 PowerFlex 70 AC Drive 20A

GC646MPPS50 Proficy GlobalCare Complete for Logic Developer - PLC Professional - 50 Seat Site License

HE693OIU907 Full-sized Genius VF OIU powered by 80-240VAC

IC610CHS100RR Rack, Non-Expandable, 115/230Vac Power Supply HiCap (5 Slots)

IC647HSTSC300M Server to Server Collector for Historian - Standard Server 300 Points (M4 Key)

IC660BBA104 Block 115Vac/125Vdc Analog Current Source 4 Inputs / 2 Outputs

IC694MDL754CA Conbal Coated. 12/24VDC Output (0.75 amps/point)Module 32 point. Requires terminal block IC694TBBx32 box style or IC694TBSx32 spring clamp. Terminal block is sold seperaby. Output response Time is 0.5ms.

IC756WDJ009K-22 DV Development Sys VB and Java, Korean, Version 2.2

MicroLogix 1500/1769 System 9399-RLD300GR RSLOGIX 5000 GETTING RESULTS GUIDE

PLC-5/1771 System 1771-P2 POWER SUPPLY, 6.5A, 120/220V AC

Distributed I/O 1794-CE1 EXTENDER CABLE FOR TERMINAL BASES, 1FT/.3M

Operator Interface 2711P-B6C8A PV PLUS 600 COLOR, KEY/TOUCH, DH+, AC PS

Support 9323-PA2ES SUPT RENEWAL CONTRACT FOR 9323PA2E