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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。
 

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150-C201NBR SMC-3 201A Smart Motor Controller

1608P-BP110A480V3 ProDySC 110 Amp Bypass

1770-CD3 Data Highway 300-300 ft Length Cable

193-DNCT-BZ1 DeviceNet Door Mount Bezel Kit

194R-S1 194R Standard Length Operating Shaft

2090-CPBM7E7-08AF20 20 m Length SpeedTec Extension Cable

2090-XXTPMP-16S90 MP-Series 90 m Length Power Cable

CP5B-0WEB-0070-AZ Shielded motor power cable for B12is motor(straight connector). 7 meters

GF-965012 Connecting FlashCable to Mitutoyo Indicator (543-11x/543-13x/543-14x/5 43-18x/543-17x).

IC200UEX010-24 Qty of 24, 14 point expansion. (8) 120VAC In, (6) 120VAC Out, 120/240 VAC Power Supply (includes IC200CBL501)

IC647ADC050 PA Dashboard Client 50 Pak