In the production workshop of a leading photovoltaic enterprise in Jiangsu Province, 12 sets of 7IS0503A-LED solar simulators from Saifan Optoelectronics are operating 24 hours a day, conducting electrical performance tests on each PERC cell leaving the factory. Data shows that after introducing the equipment from Saifan, the company's battery cell testing yield has increased by 3.2%, and it has saved over 8 million yuan in testing costs annually. As the photovoltaic industry enters the deep-water zone of "cost reduction and efficiency improvement", Saifan Optoelectronics is redefining the value standards of mass production testing equipment with industrial-grade reliability and intelligent solutions.
1. Industrial-grade performance: Seamless connection from R&D to mass production
The 3A + grade LED solar simulator specially designed by Saifan for the manufacturing industry achieves a perfect balance between precision and durability:
Rapid calibration technology: Spectral self-calibration is completed within 3 minutes after startup (traditional xenon lamps require 30 minutes of preheating), supporting high-speed testing of 1,200 solar cells per hour, meeting the cycle time requirements of GW-level production lines.
Anti-interference design: All-metal shielded housing + electromagnetic compatibility optimization, maintaining ±1.8% irradiation stability even in strong electromagnetic environments (such as plasma coating workshops), which is 50% higher than similar equipment.
Long-life light source: 100,000 hours of LED lifespan (approximately 11 years), combined with an intelligent light source management system that monitors light attenuation in real time and automatically compensates, avoiding the frequent lamp replacement of traditional xenon lamps that causes production line shutdowns.
Ii. Mass Production Value: Enhance manufacturing competitiveness throughout the entire process
1. Research and development stage: Accelerate the implementation of new technologies
When a certain TOPCon battery enterprise introduced the SE (Selective Emitter) process, it utilized the I-V characteristic curve fitting function of the Saifan simulator to precisely locate the optimization direction of the electrode contact resistance. By simulating the spectral responses under different doping concentrations, the R&D cycle was shortened by 40%, and the conversion efficiency of the first 1GW TOPCon production line was 0.7% higher than the design value.
2. Production stage: Build an intelligent test network
Saifan equipment supports seamless integration with the MES system, uploading in real time 12 key parameters such as short-circuit current (Isc) and open-circuit voltage (Voc) of each battery, with a data accuracy rate of 99.99%. Through the big data analysis of Saifan equipment, a certain photovoltaic enterprise discovered the correlation between the hidden crack defects in the slicing process and the uniformity of irradiation, reducing the defect rate from 0.8% to 0.2%.
3. Quality control stage: Establish international-level certification standards
The Saifan simulator has passed international standard certifications such as IEC 60904-9 and JIS C 8912, and supports export certification tests such as CE and UL. A component manufacturer in Zhejiang Province completed the VDE certification test using Saifan equipment. The overseas certification cycle for its bifacial double-glass components was shortened from six months to two months, quickly opening up the European market.
Iii. Industry Cases: The Common Choice of Leading Enterprises
▶ Longi Green Energy: The "Secret Weapon" for Efficiency Enhancement
At the HJT battery production line of Longi's Xixian base, the multi-angle light test function of the Saifan simulator (supporting 0-90° incident Angle adjustment) helps engineers identify the issue of light reflection loss at the battery edges. By optimizing the packaging process, the component power was increased by 3.5W, and the annual new output value exceeded 200 million yuan.
Jinkosolar: The "Light Efficiency Manager" for Cost Control
After JinkoSolar's Jiangxi factory introduced equipment from Saifan, the energy consumption per GW for testing dropped from 1.2 million kilowatt-hours to 400,000 kilowatt-hours (saving 66.7%), and the cost of replacing light sources decreased from 1.5 million yuan per year to 150,000 yuan (a reduction of 90%). The remote operation and maintenance function of the equipment (supporting wireless monitoring within 50 kilometers) has reduced the response time of engineers from 2 hours to 15 minutes.
Trina Solar: The "Light Standard" for Global Layout
Trina's Vietnam factory has established the first 3A-level testing laboratory in Southeast Asia using the Sefan simulator, solving the problem of equipment stability in tropical high-humidity environments. This laboratory has become the designated testing point for photovoltaic module certification in the ASEAN region, helping Trina increase its market share in Southeast Asia to 28%.
Iv. Intelligent Manufacturing Upgrade: Initiating the Era of Industry 4.0 Testing
The intelligent testing solution launched by Saifan Optoelectronics is driving photovoltaic manufacturing into the digital stage:
AI spectral prediction: By training algorithms with historical data, the attenuation trend of light sources can be predicted 72 hours in advance to achieve preventive maintenance.
Virtual test platform: Based on the actual measurement data of the equipment, a digital twin model is constructed, allowing the R&D department to simulate the test results of different process parameters online.
Cloud data middle platform: Supports real-time synchronization of test data across multiple factory areas. The headquarters can remotely monitor quality fluctuations at each base, increasing decision-making efficiency by 60%.
When photovoltaic electricity prices entered the "10-cent era", every 0.1% improvement in efficiency at the manufacturing end meant an increase of hundreds of millions of yuan in output value. The Saifan LED solar simulator, with its industrial-grade precision, reliability and intelligence, is becoming the core competitiveness for photovoltaic enterprises to weather the cycle. From technological breakthroughs in the laboratory to efficiency revolutions on production lines, Saifan has always been in step with China's photovoltaic industry, illuminating the global energy transition path with "Chinese precision".
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