The objective of this study is to construct a “Double-Circulation Double-Diamond” model integrating AHP, QFD, and TRIZ. This will enable the resolution of contradictions between user requirements and technical solutions in the design of highway maintenance unmanned vehicles. The construction of an efficient, safe, and iterative systematic design framework will be achieved by following these steps. The model incorporates both internal and external feedback loops into the conventional Double-Diamond framework, thereby establishing a dynamic closed-loop process of “requirement identification—technical transformation—contradiction resolution—feedback optimization.” AHP is employed to conduct a hierarchical analysis of user requirements; QFD is utilized to map these requirements to technical characteristics; and TRIZ is integrated to facilitate innovative problem-solving and solution generation. The proposed model has been demonstrated to be an effective means of achieving requirement hierarchy decomposition, technical translation, and resolution of key contradictions. MATLAB R2025b (version 25.2.0) simulations were employed to verify the role of the external feedback loop in scheme iteration and optimization. This confirmed the A* algorithm as the optimal path planning approach, which achieves a balance between efficiency and safety. The fuzzy comprehensive evaluation yielded a score of 3.142, indicating performance between “well achieved” and “fully achieved”. In comparison with conventional linear development methodologies, the “Double-Circulation Double-Diamond” model has been shown to markedly enhance the systematicness and dynamic adaptability of complex equipment design through the utilization of cross-phase feedback and methodological coupling. This approach provides a transferable design framework applicable to highway maintenance, unmanned vehicles, and other complex engineering systems.

This study presents an integrated design methodology for earthquake demolition rescue robots by combining UXMs, Kano, and QFD to improve design rationality and performance in extreme rescue scenarios. It addresses key gaps in existing approaches, particularly the lack of systematic experiential data acquisition, quantitative requirement analysis, and effective design translation. UXMs are applied to reconstruct critical task scenarios and identify high-load nodes and user experience variations. The Kano model is used to prioritise and classify user requirements, which are then translated into engineering characteristics through QFD. Based on this framework, a conceptual robot design is developed using the FBS model and evaluated through process-level simulation and usability assessment. The results demonstrate that the proposed method enables structured requirement transformation and supports traceable design decisions. Simulation indicates the consistency of task workflows and coordination among functional modules at the process level. A System Usability Scale score of 80.22 indicates a relatively high level of perceived usability at the conceptual evaluation stage. The proposed methodology provides a structured and traceable conceptual design framework for earthquake rescue robots. While the current validation is based on conceptual-level evaluation, the methodology offers a traceable design pathway that may be extended to other high-risk emergency equipment with further empirical testing.