| Theory and Method of Mechanical Design |
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| Research on failure prediction based on mechanism models and inverse application of TRIZ tools |
Runze XUE( ),Huangao ZHANG( ),Miaomiao ZHANG,Sai WANG |
| National Engineering Research Center for Technological Innovation Method and Tool, Hebei University of Technology, Tianjin 300401, China |
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Abstract Anticipatory failure determination (AFD) is a failure prediction method used to identify deficiencies and hidden risks in product design during design or manufacturing stages, serving as a powerful tool to enhance product reliability. Current AFD mainly define scenarios of successful realization of product functions at a macro level and give insufficient attention to the underlying mechanisms that drive functional realization, which affects the rationality and accuracy of failure prediction. Furthermore, the existing studies for function reversal and standard-solution reversal predominantly adopt direct semantic reversal to generate failure scenarios, which leads to relatively simplistic reversal methods. To address these issues, firstly, a mechanism-based failure prediction approach was proposed. In this approach, the mechanism model of the product was extracted, the mathematical or physical expressions of the mechanism model were used to query potential failures, and the integrated mechanism model was simulated by Simulink software to effectively query failure modes of the product. Secondly, the reversal forms of functions and standard solutions were added based on the substance-field model, and a method for obtaining failure events by reverse application of inventive principles in TRIZ (Teoriya Resheniya Izobreatatelskikh Zadatch) was proposed, forming a new path to obtain failure events. Finally, an AFD prediction process combining mechanism models and the reverse application of TRIZ problem-solving tools was established, and the failure prediction for a passive power-damping boring bar was conducted to verify the feasibility of this method. The proposed method improves the acquisition way of failure scenarios based on the traditional AFD process, effectively enhancing the rationality and accuracy of failure mode prediction, which has significant theoretical insights and practical engineering value for improving product design reliability.
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Received: 21 October 2025
Published: 27 June 2026
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Corresponding Authors:
Huangao ZHANG
E-mail: 1776364187@qq.com;zhgzwy@hebut.edu.cn
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基于机理模型和TRIZ工具逆用的失效预测研究
预期失效分析(anticipatory failure determination, AFD)是一种在设计或制造阶段发现产品设计的不足和隐患的失效预测方法,是提高产品可靠性的强有力工具。现有的AFD主要从宏观角度设定产品功能成功实现的情景,缺乏对产品功能实现机理的关注,从而影响失效预测的合理性和准确性。此外,现有研究针对功能反转与标准解反转多为直接采用语义反转后形成失效情景,反转方式比较单一。针对上述问题,首先,提出了结合机理模型的失效预测方法,在提取产品机理模型的基础上,使用表达机理模型的数学或物理公式进行潜在失效査询,并使用Simulink软件对整体机理模型进行仿真,以有效查询产品的失效模式。然后,基于物质-场模型增加功能与标准解的反转形式,并提出了基于逆用TRIZ(Teoriya Resheniya Izobreatatelskikh Zadatch,发明问题解决理论)中发明原理的失效事件获取方法,形成了失效事件获取的新途径。最后,建立了结合机理模型和TRIZ解题工具逆用的AFD预测流程,并以被动式动力减振镗杆失效预测为例,验证了该方法的可行性。所提出的方法在传统AFD流程的基础上,改进了失效情景获取方式,能够有效提高失效模式预测的合理性和准确性,这对提升产品设计的可靠性具有重要的理论意义与工程应用价值。
关键词:
预期失效分析,
机理模型,
发明问题解决理论(TRIZ),
失效预测
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