Special equipment accident analysis method based on TRIZ system function model tool

Abstract

The invention relates to the technical field of accident analysis, and discloses a special equipment accident analysis method based on a TRIZ system function model tool, and the method comprises the following steps: S1, collecting the operation data and accident occurrence data of special equipment; s2, performing function analysis based on a TRIZ system function model tool; s3, solving technical contradictions and functional contradictions by applying a TRIZ innovation principle and a contradiction matrix, and proposing a targeted technical solution; s4, performing simulation analysis; and S5, formulating and implementing an improvement scheme, formulating a design or operation improvement scheme of equipment according to a simulation analysis result and actual data, and performing actual application. By combining a TRIZ system function model tool, the invention provides a scientific, systematic and innovative special equipment accident analysis method, which has remarkable technical innovation and practical application value, can effectively improve the equipment safety, reduce accidents and provide powerful guarantee for the safe operation of the special equipment.

Description

Technical Field

[0001] The invention relates to the technical field of accident analysis, and in particular to a special equipment accident analysis method based on a TRIZ system function model tool. Background Art

[0002] With the rapid development of social economy and the advancement of industrialization, the use of special equipment is becoming increasingly extensive, including pressure vessels, elevators, boilers, lifting equipment, etc. Although these equipment play an important role in daily operation, they are prone to equipment failure and safety accidents due to various factors such as improper operation, design defects, and untimely maintenance. Accidents involving special equipment not only bring huge economic losses to enterprises, but may also have a significant impact on personnel safety and the environment.

[0003] At present, most traditional accident analysis methods rely on empirical analysis and statistical data. These methods are often limited by human judgment and lack systematicity and depth. Especially for complex and high-risk special equipment accidents, traditional methods are difficult to fully and systematically reveal their root causes. In addition, existing methods usually lack effective technical means and tools to support the implementation of accident analysis and improvement plans. Therefore, how to improve the accuracy of accident analysis and the effectiveness of solutions is still a technical problem that needs to be solved urgently.

[0004] As an innovative problem-solving method, TRIZ theory has been widely used in technological innovation and product design. Its core concept is to discover the root cause of the problem and propose innovative solutions through systematic functional analysis. However, the traditional application of TRIZ is mainly concentrated in the fields of technical problem solving and product design, and its application in special equipment accident analysis is relatively weak. Therefore, how to apply the TRIZ system functional model tool to special equipment accident analysis, and then improve the scientificity and systematicness of accident analysis, is an important challenge in the current technical field.

[0005] Therefore, we propose a special equipment accident analysis method based on TRIZ system functional model tool. Summary of the invention

[0006] The present invention mainly solves the technical problems existing in the above-mentioned prior art and provides a special equipment accident analysis method based on TRIZ system functional model tool.

[0007] In order to achieve the above object, the present invention adopts the following technical scheme, a special equipment accident analysis method based on TRIZ system function model tool, comprising the following steps:

[0008] S1: Collect the operation data and accident data of special equipment to fully understand the operation status and historical accident situations of the equipment;

[0009] S2: Perform functional analysis based on the TRIZ system functional model tool, decompose the functions of each link of the equipment, and determine the technical and functional contradictions in the system;

[0010] S3: Use TRIZ innovation principles and contradiction matrix to solve technical contradictions and functional contradictions, and propose targeted technical solutions;

[0011] S4: Simulation analysis, verifying the feasibility of the proposed technical solution through simulation tools or other simulation methods;

[0012] S5: Develop and implement improvement plans. Develop equipment design or operation improvement plans based on simulation analysis results and actual data, and apply them in practice.

[0013] As a preferred technical solution of the present invention, the step of collecting operation data and accident occurrence data of special equipment in S1 includes:

[0014] S11: Collect the operating status data of special equipment in real time through sensors and monitoring equipment, including important parameters such as temperature, pressure, vibration, etc.

[0015] S12: Extract relevant data from historical accident records, including the specific time, location, equipment status, environmental conditions, etc. of the accident;

[0016] S13: Classify and organize the collected data to facilitate subsequent systematic analysis and ensure the integrity and accuracy of the data.

[0017] As a preferred technical solution of the present invention, the function analysis step in S2 includes:

[0018] S21: Based on the TRIZ system functional model tool, disassemble the functional modules of special equipment and analyze the functional requirements, working principles and potential failure modes of each functional module;

[0019] S22: Use TRIZ’s functional matrix to analyze the interactions between different modules, identify and analyze potential functional and technical contradictions, and find out the root causes of equipment failures.

[0020] As a preferred technical solution of the present invention, the technical contradiction and functional contradiction in S3 are solved by the innovation principle and contradiction matrix of TRIZ, including:

[0021] S31: Use the separation principle and reversal principle in TRIZ innovation principles to deal with the identified technical contradictions and seek innovative methods to solve the contradictions without changing the overall function of the system;

[0022] S32: Select solutions based on the contradiction matrix of TRIZ, choose the most appropriate innovation principle according to the type of accident, and propose corresponding technical solutions.

[0023] As a preferred technical solution of the present invention, the simulation analysis step in S4 includes:

[0024] S41: Use simulation software or physical models to simulate the proposed technical solutions and compare the simulation results with actual accident data;

[0025] S42: Evaluate the simulation results to determine whether the proposed solution can effectively avoid the accident;

[0026] S43: If the simulation result is not ideal, readjust the plan and re-simulate until the optimal solution is found.

[0027] As a preferred technical solution of the present invention, the improvement solution in S5 includes:

[0028] S51: Adjust the design plan or operation process of special equipment according to the analysis results, optimize the design of key components or adjust the operating procedures;

[0029] S52: Add new monitoring items to the routine maintenance and inspection of equipment, such as regularly checking the working status of key components to prevent failures;

[0030] S53: Develop operator training programs to improve operators’ safety awareness and emergency response capabilities to ensure rapid response when accidents occur.

[0031] As a further limitation of the above solution, the accident analysis also includes the analysis of the equipment use environment and operator behavior, and the solution is further optimized by combining the TRIZ system functional model tool to consider the impact of environmental and human factors on equipment safety.

[0032] As a further limitation of the above scheme, the special equipment is any one of a pressure vessel, an elevator, a boiler, and a lifting equipment.

[0033] As a further limitation of the above scheme, the accident analysis method has strong adaptability, can be widely used in accident analysis of different types of special equipment, and has high practical application value.

[0034] The invention provides a special equipment accident analysis method based on a TRIZ system function model tool.

[0035] It has the following beneficial effects:

[0036] 1. This special equipment accident analysis method based on the TRIZ system functional model tool provides a scientific, systematic and innovative special equipment accident analysis method by combining the TRIZ system functional model tool. It has significant technical innovation and practical application value, can effectively improve equipment safety, reduce accidents, and provide strong guarantee for the safe operation of special equipment.

[0037] 2. This special equipment accident analysis method based on the TRIZ system function model tool improves the accuracy and systematicness of accident analysis. Traditional accident analysis methods often rely on experience and statistical data, and have great limitations and uncertainties. By using the TRIZ system function model tool, the present invention provides a more scientific and systematic analysis method that can comprehensively and deeply reveal the root cause of the accident and avoids the analysis that simply relies on surface phenomena.

[0038] 3. This special equipment accident analysis method based on the TRIZ system functional model tool proposes an innovative solution. Traditional accident analysis methods are often difficult to propose innovative solutions. The present invention, through the innovative principles of TRIZ, can provide innovative solutions for equipment design, operating procedures and maintenance management, thereby ensuring the safety and stability of the equipment.

[0039] 4. This special equipment accident analysis method based on the TRIZ system functional model tool has enhanced adaptability and universality. The method of the present invention is not only applicable to special equipment such as pressure vessels, elevators, boilers, and lifting equipment, but can also be adjusted and optimized according to the characteristics of different equipment types, and has strong adaptability. By flexibly applying the innovative principles of TRIZ, it can be widely used in various types of special equipment accident analysis.

[0040] 5. This special equipment accident analysis method based on the TRIZ system functional model tool reduces the occurrence of accidents and improves the reliability of equipment. Through the implementation of systematic accident analysis and improvement plans, the present invention can effectively reduce the occurrence of special equipment accidents and improve the reliability and safety of equipment. By timely discovering potential technical and functional contradictions of equipment and solving them, safety hazards can be fundamentally eliminated to ensure long-term stable operation of equipment.

[0041] 6. This special equipment accident analysis method based on the TRIZ system functional model tool is helpful to improve the safety management level. The present invention not only solves the technical problems in accident analysis, but also can promote the improvement of the safety management level of special equipment. By improving the design of equipment, optimizing operating procedures, strengthening personnel training and other measures, the safety awareness and emergency response capabilities of operators are further improved, thereby reducing the risks of human operating errors to equipment safety.

[0042] 7. This special equipment accident analysis method based on the TRIZ system functional model tool has high practical application value and can be widely used in accident analysis and improvement of special equipment, especially in the field of high-risk and high-tech equipment. It can provide strong technical support for enterprises and industries, help enterprises reduce accident rates, improve equipment safety, and thus reduce economic losses and casualties. DETAILED DESCRIPTION

[0043] Example 1

[0044] A special equipment accident analysis method based on TRIZ system function model tool includes the following steps:

[0045] S1: Collect the operation data and accident data of special equipment to fully understand the operation status and historical accident situations of the equipment;

[0046] S2: Perform functional analysis based on the TRIZ system functional model tool, decompose the functions of each link of the equipment, and determine the technical and functional contradictions in the system;

[0047] S3: Use TRIZ innovation principles and contradiction matrix to solve technical contradictions and functional contradictions, and propose targeted technical solutions;

[0048] S4: Simulation analysis, verifying the feasibility of the proposed technical solution through simulation tools or other simulation methods;

[0049] S5: Develop and implement improvement plans. Develop equipment design or operation improvement plans based on simulation analysis results and actual data, and apply them in practice.

[0050] The steps for collecting operation data and accident data of special equipment in S1 include:

[0051] S11: Collect the operating status data of special equipment in real time through sensors and monitoring equipment, including important parameters such as temperature, pressure, vibration, etc.

[0052] S12: Extract relevant data from historical accident records, including the specific time, location, equipment status, environmental conditions, etc. of the accident;

[0053] S13: Classify and organize the collected data to facilitate subsequent systematic analysis and ensure the integrity and accuracy of the data.

[0054] The functional analysis steps in S2 include:

[0055] S21: Based on the TRIZ system functional model tool, disassemble the functional modules of special equipment and analyze the functional requirements, working principles and potential failure modes of each functional module;

[0056] S22: Use TRIZ’s functional matrix to analyze the interactions between different modules, identify and analyze potential functional and technical contradictions, and find out the root causes of equipment failures.

[0057] The technical contradictions and functional contradictions in S3 are solved through the innovation principles and contradiction matrix of TRIZ, including:

[0058] S31: Use the separation principle and reversal principle in TRIZ innovation principles to deal with the identified technical contradictions and seek innovative methods to solve the contradictions without changing the overall function of the system;

[0059] S32: Select solutions based on the contradiction matrix of TRIZ, choose the most appropriate innovation principle according to the type of accident, and propose corresponding technical solutions.

[0060] The simulation analysis steps in S4 include:

[0061] S41: Use simulation software or physical models to simulate the proposed technical solutions and compare the simulation results with actual accident data;

[0062] S42: Evaluate the simulation results to determine whether the proposed solution can effectively avoid the accident;

[0063] S43: If the simulation result is not ideal, readjust the plan and re-simulate until the optimal solution is found.

[0064] Improvements in S5 include:

[0065] S51: Adjust the design plan or operation process of special equipment according to the analysis results, optimize the design of key components or adjust the operating procedures;

[0066] S52: Add new monitoring items to the routine maintenance and inspection of equipment, such as regularly checking the working status of key components to prevent failures;

[0067] S53: Develop operator training programs to improve operators’ safety awareness and emergency response capabilities to ensure rapid response when accidents occur.

[0068] Accident analysis also includes analysis of the equipment use environment and operator behavior, combined with the TRIZ system functional model tool to further optimize the solution and consider the impact of environmental and human factors on equipment safety.

[0069] Special equipment refers to any one of pressure vessels, elevators, boilers, and lifting equipment.

[0070] The accident analysis method has strong adaptability and can be widely used in accident analysis of different types of special equipment, and has high practical application value.

[0071] Example 2

[0072] Based on Example 1, this example is to analyze the accident of the pressure vessel:

[0073] In this example, the TRIZ system functional model tool is used to analyze the failure of the pressure vessel. The collected accident data shows that the main reason for the explosion of the pressure vessel is that the internal pressure control system fails to effectively regulate the pressure. Through functional analysis, it is found that the pressure regulation system has a contradiction between "high pressure / low pressure", and the traditional pressure control method cannot cope with extreme conditions.

[0074] Using the separation principle and contradiction matrix of TRIZ, a scheme for optimizing the design of the pressure regulation system was proposed, which specifically includes improving the accuracy of the pressure sensor, introducing an intelligent control algorithm, and strengthening the emergency response function of the safety valve. Through simulation analysis, it was verified that the scheme can effectively reduce the risk of explosion. Finally, the improved safety valve design scheme was applied in actual production, significantly improving the safety of the equipment.

[0075] Example 3

[0076] Based on Example 1, this example is about elevator fault analysis:

[0077] This example analyzes an accident in which an elevator suddenly stops running. By collecting the operation data of the elevator, it is found that the root cause of the elevator outage is due to the failure of the power supply system. Through functional analysis, the key technical contradictions of the power supply system are determined, especially when the power is interrupted, the system fails to activate the backup power supply in time.

[0078] Using the reversal principle of TRIZ, a solution for automatically enabling the backup power supply when power is interrupted is proposed, and a simulation analysis is performed. The results show that the improved elevator system can switch to the backup power supply in time when a power failure occurs, ensuring the continuous operation of the elevator. The solution has been successfully applied, and the elevator outage problem has been effectively solved.

[0079] Example 4

[0080] Based on Example 1, this example is to analyze the accident of the lifting equipment:

[0081] This example analyzes an accident in which a crane was overloaded. Through the collected accident data and equipment operation status information, it was found that the accuracy of the load sensor was the root cause of the overload accident. Specifically, the existing load sensor failed to accurately reflect the actual load, especially when the load fluctuated greatly, and the sensitivity of the sensor could not be adjusted in time, resulting in the failure of the overload alarm system.

[0082] Through TRIZ functional analysis, it is found that there is a technical contradiction between the load sensor and the crane load, that is, when the load is high, the sensor may not be able to accurately capture the change of the load. Therefore, the dynamic adjustment principle of TRIZ is adopted to propose a design scheme to improve the load sensor, so that it can dynamically adjust the sensitivity according to the actual operating status of the crane and improve its response accuracy under different working conditions.

[0083] After the implementation of the solution, simulation analysis and verification showed that the solution effectively avoided the occurrence of load overloading. Actual tests showed that the improved sensor can accurately detect load changes when the crane is running and trigger the alarm system in time, avoiding potential accidents caused by crane overloading. The solution has been successfully applied to multiple lifting equipment, significantly improving the safety and operational reliability of the equipment.

[0084] This invention is based on the core concept of TRIZ (Theory of Inventive Problem Solving) and solves the technical and functional contradictions in the accident analysis of special equipment through the application of systematic functional analysis and innovation principles. Its working principle is as follows:

[0085] Collect data: First, collect equipment operation data and accident data through sensors, monitoring equipment and historical accident records. These data provide comprehensive information support for accident analysis and help accurately identify potential risk points and weak links of equipment.

[0086] Functional analysis: Use the TRIZ system functional model tool to disassemble the special equipment into various functional modules, and conduct detailed functional analysis on each module. Through functional matrix analysis, identify functional and technical contradictions between different modules, such as conflicts between pressure, temperature, load and other factors.

[0087] Application of innovation principles: Combining TRIZ's innovation principles and contradiction matrix, innovative solutions are proposed for the identified technical and functional contradictions. Through TRIZ's separation principle, reversal principle, dynamic adjustment principle and other innovative principles, the design, operation and maintenance of equipment are improved to eliminate contradictions and optimize performance.

[0088] Simulation verification: After proposing a technical solution, use simulation software or physical models to simulate and analyze it to evaluate the effectiveness of the solution in actual operation. If the simulation results show that the solution fails to effectively solve the problem, further adjust and optimize the solution until the best solution is found.

[0089] Implementation of improvements: Finally, based on the simulation analysis results and actual data, a detailed improvement plan is formulated and implemented in the design, operation process and maintenance management of the equipment. By improving the design, optimizing the operating procedures, and enhancing monitoring and training, the safety and reliability of the equipment are significantly improved.

[0090] This method realizes the systematization and scientificization of special equipment accident analysis through the comprehensive application of TRIZ system functional model tools and innovation principles, ensuring that potential safety hazards can be fully identified and resolved, and practical solutions can be proposed.

[0091] The above shows and describes the basic principles and main features of the present invention and the advantages of the present invention. It should be understood by those skilled in the art that the present invention is not limited by the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A special equipment accident analysis method based on TRIZ system functional model tool, characterized in that: The following steps are involved: S1: Collect the operation data and accident data of special equipment to fully understand the operation status and historical accident situations of the equipment; S2: Perform functional analysis based on the TRIZ system functional model tool, decompose the functions of each link of the equipment, and determine the technical and functional contradictions in the system; S3: Use TRIZ innovation principles and contradiction matrix to solve technical contradictions and functional contradictions, and propose targeted technical solutions; S4: Simulation analysis, verifying the feasibility of the proposed technical solution through simulation tools or other simulation methods; S5: Develop and implement improvement plans. Develop equipment design or operation improvement plans based on simulation analysis results and actual data, and apply them in practice.

2. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1, characterized in that: The step of collecting the operation data and accident occurrence data of special equipment in S1 includes: S11: Collect the operating status data of special equipment in real time through sensors and monitoring equipment, including important parameters such as temperature, pressure, vibration, etc. S12: Extract relevant data from historical accident records, including the specific time, location, equipment status, environmental conditions, etc. of the accident; S13: Classify and organize the collected data to facilitate subsequent systematic analysis and ensure the integrity and accuracy of the data.

3. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1, characterized in that: The functional analysis steps in S2 include: S21: Based on the TRIZ system functional model tool, disassemble the functional modules of special equipment and analyze the functional requirements, working principles and potential failure modes of each functional module; S22: Use TRIZ’s functional matrix to analyze the interactions between different modules, identify and analyze potential functional and technical contradictions, and find out the root causes of equipment failures.

4. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1 is characterized in that: The technical contradictions and functional contradictions in S3 are solved through the innovation principle and contradiction matrix of TRIZ, including: S31: Use the separation principle and reversal principle in TRIZ innovation principles to deal with the identified technical contradictions and seek innovative methods to solve the contradictions without changing the overall function of the system; S32: Select solutions based on the contradiction matrix of TRIZ, choose the most appropriate innovation principle according to the type of accident, and propose corresponding technical solutions.

5. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1 is characterized in that: The simulation analysis step in S4 includes: S41: Use simulation software or physical models to simulate the proposed technical solutions and compare the simulation results with actual accident data; S42: Evaluate the simulation results to determine whether the proposed solution can effectively avoid the accident; S43: If the simulation result is not ideal, readjust the plan and re-simulate until the optimal solution is found.

6. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1, characterized in that: The improvement scheme in S5 includes: S51: Adjust the design plan or operation process of special equipment according to the analysis results, optimize the design of key components or adjust the operating procedures; S52: Add new monitoring items to the routine maintenance and inspection of equipment, such as regularly checking the working status of key components to prevent failures; S53: Develop operator training programs to improve operators’ safety awareness and emergency response capabilities to ensure rapid response when accidents occur.

7. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1 is characterized in that: Accident analysis also includes analysis of the equipment use environment and operator behavior, combined with the TRIZ system functional model tool to further optimize the solution and consider the impact of environmental and human factors on equipment safety.

8. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1 is characterized in that: Special equipment refers to any one of pressure vessels, elevators, boilers, and lifting equipment.

9. The special equipment accident analysis method based on the TRIZ system function model tool according to claim 1, characterized in that: The accident analysis method has strong adaptability and can be widely used in accident analysis of different types of special equipment, and has high practical application value.