In the intelligent manufacturing workshop of a photovoltaic enterprise in Jiangsu Province, 30 7IS0503A-LED solar simulators from Saifan Optoelectronics are conducting efficiency tests on newly produced PERC solar cells at a rate of 3 cells per minute. This beam of simulated sunlight, which has been calibrated thousands of times, acts like an indefatigable quality inspector, keeping the efficiency deviation within ±0.3%, thus building a solid defense line for the quality of each watt of photovoltaic power. As a leading enterprise in the domestic photovoltaic testing equipment market with a market share of over 40%, Saifan Optoelectronics is redefining the light testing standards with an industrial mindset, bringing laboratory-level precision into mass production workshops.
1. Mass production line compatibility: Seamless connection from the laboratory to the production line
Saifan Simulator has been specially optimized for large-scale photovoltaic production scenarios
Ultra-fast testing system: It compresses the single battery efficiency detection time to 12 seconds, which is 50% higher than that of traditional equipment. Combined with an automatic loading and unloading mechanism, it can meet the detection demand of 600 pieces per hour. Based on this, a leading enterprise has shortened the production line cycle time from 2.5 seconds per piece to 1.8 seconds per piece.
Anti-interference optical design: By adopting multi-channel filtering technology, it maintains a test accuracy of ±1.8% even in the strong light environment of the workshop, solving the space limitation of traditional equipment that requires darkroom operation and helping enterprises save 30% of workshop renovation costs.
Modular light source architecture: The lifespan of a single LED module reaches 150,000 hours, supports online replacement, reduces maintenance downtime to 15 minutes, and the annual effective operating time exceeds 8,000 hours, which is 3,000 hours longer than that of xenon lamp equipment.
Ii. Data Traceability System: Establishing the "Optogenetic Archive" for Photovoltaic Products
Build full-chain data management relying on Internet of Things (iot) technology
Chip-level ID binding: By using a visual recognition system to bind the test data of each battery to the Wafer ID, a full-process quality traceability chain from silicon material, diffusion to coating is formed. A certain enterprise quickly identified the efficiency fluctuation of a certain batch due to the deviation of PECVD process parameters with the help of this system, recovering losses of over 5 million yuan.
Production line level data dashboard: It summarizes in real time the efficiency distribution of each inspection station, EL defects and other 12 indicators. Through AI algorithms, it predicts the product yield trend 2 hours later, helping dispatchers adjust process parameters in advance and keeping the A-grade product rate of A certain component factory stable at over 92%.
Cloud-based data middle platform: Supports data summary and analysis across multiple factory areas. A certain group enterprise compared the test data from five production bases and found that the southern factory area had test deviations caused by high environmental temperatures in summer. After unified calibration, data consistency within the group was achieved.
Iii. Cost Control Capability: Meticulous calculation from the cost per watt to the entire life cycle
Saifan Simulator creates visible cost reduction value for enterprises
Energy consumption revolution: The power of a single device is only 800W, saving 12,000 kilowatt-hours of electricity annually compared to traditional xenon lamp equipment. A testing workshop with 30 devices can save 360,000 yuan in electricity fees annually, which is equivalent to reducing CO₂ emissions by 36 tons.
Consumable optimization: By eliminating the need for xenon lamp consumable replacement, the annual maintenance cost has dropped from 12,000 yuan per unit to 3,000 yuan per unit. A certain enterprise's 100-unit equipment cluster has saved 900,000 yuan in maintenance costs annually.
Space utilization: By adopting a stacked design, the floor area is only 0.8 square meters. Combined with automated track transportation, the space utilization rate of the testing area of a certain enterprise has increased by 40%, and the annual production capacity has been newly added by 2GW.
Iv. Industrial Synergy Case: Resonating with the Iteration of Photovoltaic Technology
During the mass production of TOPCon batteries, the shortwave spectral enhancement technology of Saifan simulators accurately captured the impact of boron-oxygen complexes on minority carrier lifetime, helping a certain enterprise increase battery efficiency from 25.2% to 25.8% and achieve a single-watt power generation gain of 2.3%.
The low-temperature testing mode tailored for HJT cells avoids damage to the amorphous silicon layer caused by high-temperature light, with the test repeatability error controlled within 0.2%. This has helped a certain enterprise achieve a yield rate of over 95% on its HJT production line and break even three months ahead of schedule.
In the joint EL/IV test of components, the data of Saifan equipment was linked with that of the EL detector. Through the correlation analysis of efficiency and hidden cracks, the process parameters of component string welding were optimized, reducing the power attenuation rate of the components of a certain enterprise from 2.3% to 1.8%, reaching the international first-line level.
V. Standard Output Capability: Defining the "Chinese Precision" of Photovoltaic Testing
Saifan Optoelectronics is deeply involved in the formulation of standards for the photovoltaic industry
Led the drafting of the national standard "Online Detection Method for Efficiency of Crystalline Silicon Solar Cells", incorporating the "dynamic spectral calibration" technology into the specification to address the industry pain point where data from different production lines are incomparable.
Jointly established the "Photovoltaic Testing Equipment Metrology Center" with the China Photovoltaic Industry Association, providing 500 sets of equipment calibration services for the industry each year, and increasing the international mutual recognition rate of domestic photovoltaic product test data to 98%.
Provide a Chinese case for the IEC 60904-12 international standard, incorporate Saifan's "Uncertainty Evaluation Method for Production Line-level Testing" into the appendix, and promote China's photovoltaic testing technology onto the international stage.
When the photovoltaic industry enters an era of refined competition characterized by "GW-level production capacity and 100-level efficiency", the accuracy of testing equipment directly determines the cost competitiveness of enterprises. The Saifan LED solar simulator, with its industrial reliability and laboratory precision, has become a key fulcrum for photovoltaic enterprises to transition from "scale expansion" to "quality breakthrough", ensuring that every cell and every module can stand the test of sunlight.
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