In the ceramic tile flexural testing machine, high-precision load sensors and servo control systems are precisely matched to achieve accurate measurement of the fracture modulus and failure strength of ceramic tiles, making them the core components of the testing machine.
High precision load sensor: the "nerve endings" for force perception
The load sensor is the "sensing organ" of the testing machine, whose core function is to convert the small force values generated when ceramic tiles break into quantifiable electrical signals. Taking the QJ211S testing machine as an example, it adopts high-precision sensors from the United States, with a load resolution of up to 500000 yards and constant resolution throughout the entire process. The effective force measurement range covers 0.02% to 100% of the full range, and the error is controlled within ± 0.5%. This design ensures the capture of the entire process force value from the initial force on the ceramic tile to the moment of fracture, even in the face of small deformations in thin ceramic tiles (such as thickness ≤ 6mm), data can be accurately recorded.
The sensor is wrapped with a 5mm thick rubber layer on the outside, which not only protects the sensor from impact, but also reduces local stress concentration of the sample through flexible contact, avoiding measurement deviation caused by fixture rigidity. For example, when testing glazed tiles, the rubber layer can prevent the glaze from peeling off and affecting the sensor reading, improving the repeatability of the test.
Servo control system: a dynamically loaded 'smart brain'
The servo control system is the "control center" of the testing machine, which achieves precise coordination of loading speed, force value, and displacement through a closed-loop feedback mechanism. Taking the DKZ-II testing machine as an example, it adopts a Japanese Panasonic fully digital AC servo controller, combined with an embedded Windows operating system, which can display the test curve in real time and automatically calculate the fracture modulus. The system supports three loading modes: force speed, displacement speed, and programming. The loading speed range covers 0.01-300mm/min, with a speed accuracy of ± 0.5% of the indicated value, meeting the loading rate requirement of "500N/(mm ² · s)" in GB/T3810.4-2016 standard.
The advantage of servo systems lies in their dynamic response capability. When the ceramic tile approaches the fracture point, the system can automatically adjust the loading rate to avoid data distortion caused by inertial overload. For example, when testing large-sized ceramic plates (such as 1000 × 1000mm), the system can load them in stages through programming mode, first eliminating the gap between the sample and the fixture at low speed, and then accelerating to the target speed to ensure a balance between testing efficiency and accuracy.
Technical collaboration: optimization of the entire chain from data collection to result output
The collaborative work of high-precision sensors and servo control systems has built a complete closed loop of "perception decision execution". The sensor collects real-time force value data and transmits it to the control system. The system dynamically adjusts the loading strategy based on preset parameters (such as loading rate and span), and displays the test curve intuitively through the touch screen interface. After the test is completed, the system automatically calculates the fracture modulus (R) and failure strength (σ) without manual intervention, significantly reducing operational errors.
Application scenarios and industry value
This technology combination has been widely used in building material testing, scientific research institutions, and quality supervision fields. For example, when testing the frost resistance of ceramic tiles, the system can simulate an environment ranging from -30 ℃ to+50 ℃, combined with servo controlled constant speed loading, to evaluate the effect of temperature cycling on the fracture modulus; When developing new ceramic materials, engineers can set multi-stage loading curves through programming modes to simulate complex stress scenarios in actual use, providing data support for material optimization.