融合失效物理与虚拟试验的MEMS传感器寿命预测方法
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中国航空工业集团有限公司北京长城计量测试技术研究所,北京

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A virtual life prediction method for MEMS sensors integrating physics of failure and virtual testing
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Beijing Great Wall Metrology and Testing Technology Research Institute,Aviation Industry Corporation of China,Beijing

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    摘要:

    针对高可靠MEMS传感器整机寿命验证中加速试验成本高、现有虚拟方法缺乏系统建模与不确定性量化等瓶颈,本文提出一种基于失效物理(PoF)的高保真虚拟评估方法。通过多尺度数字样机与热–振耦合仿真获取局部应力,构建模块化PoF模型库预测单点寿命;创新采用物理来源驱动的混合概率分布量化制造与环境不确定性;并基于“器件内多模式融合”与“器件间首达失效”两级机制预测整机TTF。以MPU9250验证,经自主开展的热-振联合物理实验验证,样机精度高(壳温偏差≤±0.2℃,模态误差<5%),整机TTF达7961 h(日均工作12 h下寿命约1.82年),薄弱环节识别准确。本文所提方法无需大量物理试验,显著提升评效率与可信度。

    Abstract:

    Aiming at the bottlenecks of high cost of accelerated tests and the lack of systematic modeling and uncertainty quantification in existing virtual methods for the whole machine life verification of high-reliability MEMS sensors, this paper proposes a high-confidence virtual evaluation method based on Physics of Failure (PoF). By obtaining local stress through multi-scale digital prototypes and thermal-vibration coupling simulation, a modular PoF model library is constructed to predict the single-point life; a hybrid probability distribution driven by physical sources is innovatively adopted to quantify manufacturing and environmental uncertainties; and the Time To Failure (TTF) of the whole machine is predicted based on the two-level mechanism of "multi-mode fusion within the device" and "first failure between devices". The prototype has been verified through a self-conducted combined thermal-vibration physical experiment using the MPU9250, demonstrating high accuracy (with a shell temperature deviation of ≤± 0.2℃and a modal error of <5%), with the whole machine Time To Failure (TTF) reaching 7961 h (about 1.82 years under 12 h daily operation), and accurate identification of weak links. The proposed method requires no large-scale physical tests, significantly improving evaluation efficiency and credibility.

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  • 收稿日期:2026-02-15
  • 最后修改日期:2026-04-26
  • 录用日期:2026-04-27
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