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現代航空發動機正朝著高溫、高壓、高轉速的方向發展［1］，其上愈加惡劣的工作環境不可避免地對數控系統中傳感器的穩定工作產生不利影響，導致傳感器故障發生，進而干擾控制系統使發動機性能下降［2］。因此，提高傳感器的可靠性對發動機安全、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構進行觀察，非金屬部分無法清晰顯現。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 CT 技術能清晰、直觀、準確地呈現被檢測物體內部的結構( 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、位置和大小。在工業、農業領域有著廣泛的應用［3 ～ 7］。工業 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動機數控系統的高壓壓氣機進口總溫傳感器的故障現象，利用工業 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

某型航空發動機數控系統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，結構示意圖如圖 1 所示，主要由不銹鋼外殼、薄膜鉑電阻、轉接導線、墊塊等組成，其中薄膜鉑電阻的引線與轉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，出現輸出跳變。根據傳感器的結構特點，可以推斷傳感器內部存在接觸不良現象。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)生產的 X 射線高分辨率微焦點工業 CT 系統。該系統具備180 kV 微焦點定向式 X 射線管，細節分辨能力可達 1 μm;高對比度的 14 位數字平板式探測器，分辨率( 像素大小)200 μm × 200 μm。系統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，調節射線源至故障件的距離以實現高比例放大成像。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 數據采集和圖像重建軟件得到故障件特定的截面圖像。

2． 2 檢測結果與分析

工業 CT 是基于不同密度的物質對 X 射線的衰減系數不同，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。因此，傳感器內部的金屬部分( 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接導線的焊點，以及在焊點根部的多股轉接導線上出現了一個斷點。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接導線呈松散狀態。 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。從圖中可以看出轉接導線在感溫元件內的分布以及其周邊的灌膠狀況。該圖同樣顯示出轉接導線比較松散，部分小股線束已經斷裂。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域) ，說明轉接導線周邊的灌膠不充分，有氣泡、空腔存在。
 

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Motion Control 8720MC -D078-AN- 78 AMP C CHASSIS DRIVE, OPEN ENCL., LESS OPTIONS

BC646MRA075 View Runtime 75 I/O

IC300OCS990 Starter Kit includes IC300OCS035 and IC300OSW232. No simulator. Limited one per customer

IC752WTE050 Display Station 2000 Series - 10.4" active matrix VGA (640x480) resistive touchscreen, Pentium 333MHz, 128MB RAM, 6.4 GB HD, Ethernet, 300pt count CIMPLICITY HMI, field detachable front/rear housing and Win NT

MTR-3T44-J-R-0-M-0-MODRR Servo Motor MOD=Keyway

20AC8P7A0AYNNNC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC011A3NYNACASE PowerFlex 700S AC Drive 20D

20G1ALD617AN0NNNNN PowerFlex 755 AC Packaged Drive

25B-D030N104 PowerFlex 525 15kW (20Hp) AC Drive

2715-B10CA PanelView 5500 10.4 in. Graphic Terminal

FR-E540-5.5K 10KVA 13A 5.5KW 3相AC380V/50Hz/60Hz

1492-L6T-B IEC Term Blck 8.1x90x38mm Spr Clp

1494F-D400 Disconnect Switch

軟啟動器 3RW44346BC34

ET 200SP 6ES7155-6AA00-0BN0 IM 155-6 PN 標準型PROFINET接口模塊，含總線適配器 BA 2xRJ45

1585D-D4TBJM-0M6 Micro D-Code, QD Style Ethernet Media

1747-M15 SLC EEPROM Memory Module Adaptor

1794-ADNK Flex DeviceNet Adaptor

194E-AA16E 194E Load switch