Photovoltaic factories are calculating the unnecessary money of "lamp replacement + electricity bill", aerospace teams are worrying about "inaccurate measurement in extreme environments", and car manufacturers are holding back orders that "fail to pass the certification" - the "universality shortcoming" of light testing equipment is slowing down the innovation pace of various industries. Saifan Optoelectronics has been deeply engaged in the optoelectronics industry for 20 years. Focusing on the pain points of the photovoltaic, aerospace, automotive, and scientific research fields, it has developed a "customized LED light testing solution". With "100,000 hours of maintenance-free operation, ±0.3% high precision, and 650W low power consumption" as its core, it enables every industry to use "cost-effective, reliable, and adaptable" light testing equipment.
Photovoltaic industry: Module testing solution - No lamp replacement required for 11 years, 1GW production line saves 200,000 yuan in electricity fees annually
"Eight xenon lamp simulators, with a monthly electricity bill of 20,000 yuan. Replacing the lamps costs 48,000 yuan a year. Over three years, the operation and maintenance costs are even higher than the purchase price of the equipment!" " The account book of Mr. Wang, the factory director of a certain TOPCon module factory, reveals the common predicament of the photovoltaic industry. The LED solar simulator solution customized by Saifan for the photovoltaic industry takes a dual approach of "cost reduction and efficiency improvement".
Where has the cost been reduced? It adopts a 128-channel LED light source with self-packaged technology, with a lifespan of up to 100,000 hours (11 years if used for 8 hours a day), completely eliminating the cost of lamp replacement. The power consumption of the 650W entire machine is only 22% of that of xenon lamps. The monthly electricity cost for 8 units of equipment has dropped from 20,000 yuan to 4,500 yuan, and the annual electricity cost savings for a 1GW production line exceed 200,000 yuan. Engineer Wang did the math: "Previously, the three-year operation and maintenance cost was 150,000 yuan. Now, for the Saifan equipment, the three-year operation and maintenance only costs 16,000 yuan. The money saved can buy two more testing devices." "
Where has the efficiency been improved? In response to the EL testing requirements of components, the solution is equipped with A "real-time spectral calibration algorithm", with a spectral matching degree of A + level in the 400nm-1100nm range, a reduction accuracy of over 98% in the 780nm near-infrared region, a test data deviation of ≤±0.3%, and a consistency of 99% with TUV laboratory data. The equipment is linked with the MES system of the production line to automatically generate test reports. It can test 120 components per hour, and the A-grade product rate has increased from 88% to 93%, reducing defective product losses by 12 million yuan annually.
Aerospace field: Extreme environment testing solution - Stable operation from -40℃ to 60℃, 7-day customized space spectrum
The test of spacecraft battery wings needs to simulate the extremely cold of -40 ℃ in space. The light intensity drift of the xenon lamp equipment exceeds 5%, and the data is simply not daring to be used. The solar panel test of the Mars rover requires AM0 + infrared enhanced spectroscopy. Customizing foreign equipment will take three months. The project will definitely be delayed. The anxiety of Engineer Li from a certain academy of China Aerospace was alleviated by Saifan's customized aerospace solution.
How to withstand extreme environments? The solution adopts a 6061-T6 military-grade body and airtight packaging design, like putting on a "space protective suit" for the equipment. Within the temperature range of -40℃ to 60℃, the temperature fluctuation is ≤±0.3℃, and the light intensity deviation in the 720-hour low-temperature irradiation test is ≤±1.2%, perfectly reproducing the lighting characteristics in the vacuum environment of space. In the test of the battery wing of a certain space station, with the help of this solution, the new coating selected by the team extended the in-orbit life of the battery wing by three times.
How can customized demands be met quickly? In response to the special spectral requirements of deep space exploration, Saifan's modular design supports full-band adjustment from 280nm to 1800nm. During the Mars exploration mission, the "AM0 + Infrared Enhancement" module was developed in just 7 days, increasing the irradiance in the 800-1100nm band by 30% and the power generation efficiency of the Mars rover's solar panels by 22%. The customization cycle is 87% shorter than that of foreign countries. "Previously, it took three months to wait for foreign equipment, but now Saifan can complete it in just seven days. Our space projects no longer have to be held back." " Engineer Li said.
Automotive industry: Automotive-grade photovoltaic testing solution - Temperature resistance up to 60℃+ UV resistance, certification cycle shortened by 60%
For the rooftop photovoltaic panels to pass the automotive standard certification, they need to simulate the 60℃ high temperature in the Sahara and the strong ultraviolet rays in Northern Europe. The xenon lamp equipment reported errors as soon as the temperature reached high, and the certification was rejected three times, resulting in a loss of 5 million yuan in orders. The predicament of Engineer Zhang, the testing supervisor of a certain new energy vehicle company, is a typical problem in automotive light testing. Saifan's vehicle regulation solution directly addresses the two core aspects of "weather resistance + certification".
How to measure the automotive environment? The solution is equipped with a "high-temperature stable light source", with a luminous efficiency fluctuation of no more than ±2% in a 60℃ environment. At the same time, it enhances the output of the 300-400nm ultraviolet band to simulate strong ultraviolet aging scenarios. After testing, the lifespan of the roof photovoltaic panels has been extended from 5 years to 8 years, and it has successfully passed the ISO 105-B06 anti-ultraviolet certification. After a certain car manufacturer tested this solution, the rooftop photovoltaic panels passed the certification in one go, saving two months compared to before.
How to verify the authentication data? The equipment has passed international certifications such as IEC 60904-9 and JIS C 8912. The test data have been recognized by German TUV and American UL, and there is no need for secondary retesting. With the help of this solution, the certification cycle for roof photovoltaic panels of Mr. Zhang's team was shortened from three months to 1.2 months, successfully entering the European market and increasing annual sales by 42%. "Previously, the data had to be repeatedly revised for certification. Now, the reports issued by Saifan equipment are directly recognized, and the efficiency has more than doubled." "
Research field: Multi-scenario photocatalytic scheme - 1% precision control, Experimental data as stable as a "ruler"
Photocatalytic hydrogen production requires precise adjustment of the proportion of ultraviolet light, and plant growth needs to simulate day and night light. Traditional equipment only has a fixed spectrum, and the experiment has been stuck for half a year with no progress. Professor Zhou from Qingdao University of Science and Technology is troubled by common problems in scientific research light testing. Saifan's customized research solutions transform into "the palette of light".
How do I adjust the spectrum? The solution supports 1% precision adjustment in the ultraviolet (300-400nm), visible and near-infrared bands. The light intensity can be continuously switched from 1W/m² (weak light) to 1500W/m² (strong light), and it can also simulate 8 scenarios such as day and night alternations and pulsed light. Professor Zhou's team increased the photocatalytic hydrogen production efficiency by 40% by adjusting the proportion of ultraviolet light from 5% to 15%. The results were published in "Applied Catalysis B: Environmental".
How can the data be stable? The equipment adopts "distributed heat dissipation + microchannel water cooling". During operation, the surface temperature is only 38℃, the fluctuation of the experimental environment is ≤±0.5℃, and the data repeatability reaches 98%. "Previously, students would rush to conduct experiments during the low-temperature period. Now, they can obtain stable data at any time, and the research progress has been accelerated by 50%." " Professor Zhou mentioned that a certain agricultural research group used this plan to simulate the highland light, and the yield of the barley variety they cultivated increased by 25%, which has been promoted and planted in Qinghai.
Full-cycle service: Industry-exclusive service package, making usage "worry-free"
Saifan is well aware that the service demands vary across different industries. Therefore, it has launched an "industry-specific service package" : for the photovoltaic industry, it offers "production line linkage debugging" to ensure seamless integration between equipment and the MES system. In the aerospace field, we offer "extreme environment calibration services", providing on-site low-temperature irradiation calibration once a year. The automotive industry offers "certification connection services" to assist in connecting with TUV and UL certification bodies. In the field of scientific research, we offer "spectral customization training" to help teams master the 1% accuracy control skills.
The seven major spare parts centers across the country ensure that the fault response time is no more than 2 hours, and the average repair time is only 4 hours. When a photovoltaic factory's equipment suddenly broke down, engineers from Saifan arrived at the scene in 2 hours and resumed production in 3 hours. Free on-site maintenance is provided for equipment that has been in use for three years to ensure that the accuracy does not decline. The equipment in A certain scientific research laboratory has been in use for five years, and the spectral matching degree still remains at the A + level.
Today, Saifan LED solar simulators have served over 200 customers worldwide. The repurchase rate in the photovoltaic industry is 90%. In the aerospace field, it has supported 12 national-level tasks. In the automotive industry, it has helped 8 automakers pass automotive-grade certifications. In the scientific research field, it has promoted more than 20 achievements to be published in SCI journals. Whether it is cost optimization for photovoltaic production lines or precise testing for space missions, Saifan can provide customized solutions that are "tailored to the industry's taste", making light testing truly an "innovation accelerator".
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