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PXI-4498,

PXI-4498

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现代航空发动机正朝着高温、高压、高转速的方向发展［1］，其上愈加恶劣的工作环境不可避免地对数控系统中传感器的稳定工作产生不利影响，导致传感器故障发生，进而干扰控制系统使发动机性能下降［2］。因此，提高传感器的可靠性对发动机安全、可靠工作极为重要。通过对传感器故障件的科学诊断，探索其失效机理，将有利于传感器的迭代设计，进而不断提升可靠性。传统的传感器故障检测方法存在下列局限性: 1) 无损检测时，一般采用 X 射线机，仅适用于对传感器的金属结构进行观察，非金属部分无法清晰显现。且一般只能二维成像，无法三维立体显示。2)破坏性观察。对故障件进行分解以查找故障点，容易造成故障点在分解过程中被破坏而无法定位。

工业 CT 技术能清晰、直观、准确地呈现被检测物体内部的结构( 包括金属及非金属部分的三维信息可视化) 、密度变化以及缺陷的性质、位置和大小。在工业、农业领域有着广泛的应用［3 ～ 7］。工业 CT 的上述特点，使其成为传感器故障无损、准确、高效和全方位检测行之有效的手段之一，对传感器可靠性的提升具有重要作用。

本文针对某型航空发动机数控系统的高压压气机进口总温传感器的故障现象，利用工业 CT 技术对其进行了无损检测，从而快速、准确地定位到故障点，并利用其提供的传感器内部信息对故障原因进行了分析，采取了相应的改进措施。最后通过试验验证了改进措施的有效性，结果表明该传感器的可靠性得到了显著提高。

1 、故障描述

某型航空发动机数控系统的高压压气机进口总温传感器( 以下简称“传感器”) ，为铠装薄膜铂电阻式温度传感器。其核心部件为感温元件，结构示意图如图 1 所示，主要由不锈钢外壳、薄膜铂电阻、转接导线、垫块等组成，其中薄膜铂电阻的引线与转接导线采用火焰硬钎焊连接。
传感器的故障为在使用过程中，出现输出跳变。根据传感器的结构特点，可以推断传感器内部存在接触不良现象。但受制于前期的故障检测手段，始终未能准确地定位故障点，无法对传感器进行结构和工艺上的改进，严重影响了传感器的可靠性提升。


2 、CT 故障定位

2． 1 检测设备与试验条件

传感器故障件检测设备采用的是通用电气公司( GE)生产的 X 射线高分辨率微焦点工业 CT 系统。该系统具备180 kV 微焦点定向式 X 射线管，细节分辨能力可达 1 μm;高对比度的 14 位数字平板式探测器，分辨率( 像素大小)200 μm × 200 μm。系统可以获得各种大小试件的高精度3D 信息。

试验时，利用微焦点锥束 CT 对传感器故障件进行检测。为获得高分辨率 CT 图像，微焦点 X 射线源采用了低功率以获得更小的焦点尺寸，调节射线源至故障件的距离以实现高比例放大成像。故障件断层扫描间距为 0． 05 mm，通过计算机断层扫描后，利用 CT 数据采集和图像重建软件得到故障件特定的截面图像。

2． 2 检测结果与分析

工业 CT 是基于不同密度的物质对 X 射线的衰减系数不同，从而在重构图像中显示不同的灰度差异，进而分辨不同的物质。因此，传感器内部的金属部分( 如铂电阻引线、导线) 、非金属部分( 如热缩套管、胶黏剂) 及空腔能很好的区分开来。

图 2 是传感器故障件的感温元件部位在某一深度处的CT 纵向二维切片图像。从图中可以明显地看到铂电阻引线与转接导线的焊点，以及在焊点根部的多股转接导线上出现了一个断点。由于未对故障件进行任何破坏性的观察，因此可以确定该断点是在工作过程中形成的。并且从图中可以看出多股转接导线呈松散状态。 图3 是传感器故障件的感温元件部位在上述断点附近的 CT 横向二维切片图像。从图中可以看出转接导线在感温元件内的分布以及其周边的灌胶状况。该图同样显示出转接导线比较松散，部分小股线束已经断裂。此外，图像中明显有多处面积较大、颜色较深的部分( 例如图中用白线圈出的区域) ，说明转接导线周边的灌胶不充分，有气泡、空腔存在。
 

AR-B1474

801-8422-01 M

MB896F-R

1492-PDEC1 HOLE PLUG

6ED1055-1HB00-0BA0 LOGO!DM8 24R, 4DI/4DO

SIMATIC HMI 系列面板 6AV2123-2MA03-0AX0 KTP1200 Basic DP 12 寸触摸 + 按键

1497A-A12-M6-0-N Control Power Transformer

1732E-IB16M12R ArmorBlock 16 Point Input

1756-OB16I ControlLogix 16 Point D/O Module

188-K1B400-N Miniature Circuit Breaker 40 A

194E-FA80E-P11-PE 194E Load switch

2090-CFBM7DF-CDAF09 MP-Series 9m Feedback Cable

2090-U5PM-D0909 Ultra 5000 9m Interface Cable

BC646MVSU02 View Standard Edition Upgrade from View for QuickPanel View Standard Edition with Proficy GlobalCare Complete

GC647AUR025 GC Universal Reporting Client 25 pak

IC200ACC414 The ACC414 is a long term battery for the VersaMax Micro 20, 23, 28, 40 and 64 point CPUs. The battery will backup upto 7 years.

IC646CSPR010 Proficy Cause+ for Intelligent HMI/SCADA Runtime Server - 10X monitored KPIs

IC647IFPLSR00075M iFIX Plus SCADA 75 I/O Server (M4 Part)

IC660MLA105 Label for IC660BBA105 (Qty 100)

IC697ALG444 Analog Input Expander, Current, 16 Channels gold plated terminal. WARNING: The IC697ALG444 module must be matched with IC697ACC775 terminal block ONLY. IC697ACC775 is included with the module.

IC760STA100 StationPortal. Stand-alone I/O device supporting Ethernet. Includes universal power supply.

FlexLogix System 1794-STRT1DE FLEXLOGIX STARTER KIT GERMAN

GuardPLC Systems 1753-PCSUSB RSLOGIX GUARD PLUS FOR GUARDPLC - USB HARDLOCK

Process Control 1757-UPGSIFZA UPGRADE APPLICON QUICKBUILDER I/F

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Motion Control 8720MC -D180-AN- 180 AMP D CHASSIS DRIVE, OPEN ENCL., LESS OPTIONS

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IC300PDA001 OCS Handheld Programmer

IC754CKL12CTD Starter Kit, 12 TFT Ctrl Loaded, 24VDC"

MTR-3T45-I-R-B-M-0RR Servo Motor Metric 24V Brake

PCI-6713

STM-5 R1.5

PCA-6186E2

Allied Telesyn安奈特 AT-2711FX/LC

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PIO-16/16B(PCI)

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ET 200SP 6ES7193-6AP40-0AA0 BA 1×SCRJ光纤/1×FC 快连式

1585D-E4TBDE-0M3 Micro D-Code, QD Style Ethernet Media

1751-SLBA SynchLink Fiber Base Block

1794-IB10XOB6 Flex 10 Input 6 Output Digital Module

194E-AA20E-P11-TN 194E Load switch

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HE693OIU297 Compact VF Genius w/4-line display, powered by 24VDC

IC610CCM105RR Series One Plus Data Communications Unit (DCU)

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193-ESM-VIG-60A-E3T E300/E200 60 Amp Sensing Module

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GA647IFESGDV00900 GCA iFIX Optn: ESig & ERec 900 I/O Dev

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IC647HSTCC10KM Calculation Collector for Historian - Standard Server 10000 Points (M4 Key)

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IC693MDL750RR 12/24 Vdc Output, Negative Logic (32 Points)

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TGT-000A-2-0 Target 2-Axis Motion Control Module

AKD-P02406-NBEC-0000

FSC-1815

OSCILLOQUARTZ 956.300.469-9

超微P3TDE6

TVGA8900D-R

KJ020800

ATIO-032575B

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150-C3FBD-8L Encl. SMC-3 0.125 Smart Motor Controller

1609-P5000E Uninterruptible Power Supply P UPS Acces

1771-CP2 1771-P7 Power Supply Cable

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198-H4 MECHANISM CIRCUIT BREAKERFOR STARTER

2090-CPBM7E7-16AF02 MP-Series 2m Length Pwr and Brake Cable

2094-AC16-M03-S Kinetix 6000 Integrated Axis Module

CP9I-0MPB-0140-AZ Alpha 50HVis motor power cable (14 meter)

GFK-0398 Series 90-70 PLC Genius Bus Controller User's Manual

IC200UEX264 VersaMax Micro 64 point expansion (40) 24VDC inputs, 24VDC source outputs with ESCP, 24VDC power supply. Compatible with Micro 20/40/64 revision -Bx hardware only version 4.0 firmware and above.

IC647APC010 PA ProductionClient 10 Pak

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IC693CHS397 Base, CPU, 5 Slots, Use With CPU331/CSE331 and above

IC754DVNS01 DeviceNet Slave for QP View

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SLC/1746 System D1747-6.13 REMOTE I/O ADAPTER MODULE USER MANUAL

Distributed I/O 1734D-IA8XOA8S 120 VAC 8 IN 8 OUT, DNET COMMS, SPRING

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GQPM-DEM-L02 QUICKPANEL MINI DEMO GE LABEL

IC646MSS101 Logic Developer - State Standard w/Programming Cable

MTR-3T45-I-R-B-M-0 MTR-Series Servo Motor, Resolver, Metric, 24V Brake

ST-122F STXi input module 16 points, Negative Logic, 12V/ 24VDC (connector type)

SCXI-1128

PCL-724

特伦顿 92-005927-603

MS-S0651

FHP24SX-U

PCM-4896

1492-RCDA4A63 Residual Current Device 63 A

存储卡 6ES7952-1KT00-0AA0 FEPROM 存储卡， 32M

变送器 3RS10 40-2GW50

1497-G-CXSX-0-N Control Circuit Transformer

1606-XLDNET8 1606 Power Supply

1762-OW16 MicroLogix 16 Point Relay Output Module

188-K3D080 Miniature Circuit Breaker 8 A

194L-HCDC-001 IEC Control And Load Sw Actuator

2090-CPBM7DF-08AA02 MP-Series 2m Power and Brake Cable

2090-XXNPMF-14S03 Kinetix Drives 3m Standard Cable

BC647TPR075 CIMPLICITY HMI ProServer 75 I/O Runtime System with Proficy GlobalCare

GC647PRTOSI GlobalCare Complete - Proficy Portal OSI PI Connector Ver 3.0

IC200MDL743LT OUTPUT 5/12/24VDC NEG LOGIC 0.5A PER PT (1 GROUP OF 16) 16PT (LT)

IC646PHA935 PA-70H with 935 CPU - AC

IC647MSAM MSA:Mine Safety DAN

IC684TR000321 CIMPLICITY PMCS (Level 1) (4 Days)

IC697VAL216 Remplacement is Embedded VME-3122A-420000.Contact GE IP Embedded for details.

IC800SSI228P2RR 28A, 230V, Profibus S2K Servo Controller for S-Series Motors

SLC/1746 System 1747-L542P PRO-SET 200 - 5/04 - 32K

Industrial Computers 6181P-12NPXPHDC VERSAVIEW INTEGRATED DISPLAY COMPUTER 12-INCH TFT

Application-specific products 9358-PBANT10ENE RSBATCH NT FOR PROCESSLOGIX ARCHIVER 10 UNITS

Operator Interface 2711-B5A9L3 PV550 MONO KEY&TOUCH, DH+ & RS232 PRINT

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Support 9393-RSCOMP500R SUPT REINSTATEMENT CONTRACT FOR 9393COMP500

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Motion Control MPL-A4540C-MJ24AA MOTOR,SERVO,10.2 NM,1500RPM,MULTI,230V,BRK,13KG

Motion Control 2090-XXNFMP-S30 CABLE,NON-FLEX,MOTOR FEEDBACK,MP/1326AB,30M

CBL-T7-MB-20 Power/Brake Cable, MTR-3T1x & MTR-3T2x Series Servo Motors, 20 Ft.

IC641PCC016 Toolkit, Function Block, C

IC800SSD107RS1 7.2A, 115/230V, S2K Servo Drive for MTR Series Motors

PR-PAT-BRK01 Proficy PAT - Driver For Bruker Ftir Spectrometers

PXI-6120

ATX6022-14G

MIC-3390

AX98690

PCA-6184E2

PEAK639VL2

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1495-N34 Electrical Interlock

行程开关 3SE53120SD11

运行版软件 6AV2105-0MA04-0AA0 SIMATIC WinCC Runtime 专业版 65536 PowerTags V14

1585J-M4TBJM-5 RJ45 Ethernet Media

1756-OF8 ControlLogix 8 Pt A/O I or V Module

188-K1C040 Miniature Circuit Breaker 4 A

194E-GA32E-P22 194E Load switch

2090-CFBM7DF-CEAA04 MP-Series 4m Servo Feedback Cable

2090-UXCK-D15 Ultra Series Breakout Board Kit

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IC200ALG264 Analog input 15 bit current 15 channel

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IC660MLS101 Label for IC660BBS101 (Qty 100)

IC697BEM741RR FIP Bus Controller 9070

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