In fields such as photovoltaic cell efficiency calibration, space irradiation testing of aerospace materials, research on photocatalytic reaction kinetics, and regulation of plant photomorphogenesis, the precision of the "controllable light environment" directly determines the validity of experimental data and production efficiency. Based on 20 years of accumulation in optoelectronic technology, Saifan Optoelectronics, with "hybrid light source collaborative drive + multi-dimensional precise light control + extreme scene engineering adaptation" as its core, has developed A solar simulator that achieves A + level spectral matching degree across the entire 350nm to 1100nm band and a light intensity stability of 0.08%/h. At the same time, through modular design, it meets the customized demands of multiple industries and has become a benchmark device for the construction of high-precision light environments.
I. In-depth Analysis of Technical Architecture: Precise Control of the Entire Chain from Light Source to Algorithm
The technical advantages of the Saifan solar simulator stem from the collaborative design of "breaking through the hardware performance limit + intelligent empowerment of software algorithms". Its core architecture can be decomposed into five key modules, and the technical selection and design logic of each module directly determine the overall performance of the equipment.
1. Hybrid light source system: Light source selection and collaborative control based on spectral complementarity
Traditional single light sources cannot meet the high-precision requirements across the entire wavelength range. Saifan has achieved dual optimization of spectrum and energy through a hybrid architecture of "short-arc xenon lamps + multi-channel LED arrays". The selection logic and control technology are as follows:
Selection basis for short-arc xenon lamps:
The imported 1500W ultra-high pressure short-arc xenon lamp (model: XBO 1500W/HS) is selected. This lamp has the following core advantages:
The color temperature is stable at 5500K±200K, and the color temperature matching degree with the visible light band of the sun (400nm-800nm) reaches 98%.
The continuous operating life is 1000 hours, and the light attenuation rate is ≤5% (the light attenuation rate of traditional xenon lamps is ≥15%).
The pulse start time is ≤1 second, supporting rapid response to test requirements.
To address the issue of insufficient energy in the near-infrared band (800nm-1100nm) of xenon lamps, the curvature of the condenser was optimized through optical simulation software (ZEMAX), increasing the energy utilization rate of this band by 20%.
Design logic of LED supplementary light array
To address the energy gap of xenon lamps in the 350nm-400nm ultraviolet band and the 800nm-1100nm near-infrared band, a 128-channel high-power LED array is designed. The specific configuration is as follows:
Band range
LED chip model
Power
Driving current
Core role
350nm-400nm
Cree XP-U3 (365nm)
30,000 per piece
700mA
Supplement ultraviolet energy to meet the requirements of photocatalytic testing
800nm-900nm
Osram SFH 4770S
50,000 per piece
1000mA
Enhance near-infrared energy, suitable for photovoltaic tandem cell testing
900nm-1100nm
Epistar EPI-L940
50,000 per piece
1000mA
Covering long-wave near-infrared, it meets the aging test requirements of aerospace materials
Each LED channel is equipped with an independent DC-DC constant current driver module (output current stability ±0.01%), supporting continuous power adjustment from 0 to 100%. Energy complementarity with xenon lamps is achieved through spectral fitting algorithm, ensuring that the full-band spectral matching degree is ≤±2% (IEC 60904-9 A + class standard).
Engineering implementation of optical uniform light system
It adopts a three-stage uniform light design of "aspheric condenser + integrating sphere + cosine corrector" to solve the problems of poor uniformity and large energy loss in traditional uniform light systems:
Aspheric condenser: Made of quartz material (light transmittance ≥99.5%), the radius of curvature has been optimized through optical simulation, increasing the energy focusing efficiency of the light source by 35%.
Integrating sphere: Inner diameter 500mm, inner wall coated with PTFE diffuse reflection material (reflectivity ≥99%, resistant to ultraviolet aging), equipped with 3 light inlet and 1 light outlet, achieving uniform light intensity through multiple diffuse reflections of light.
Cosine corrector: It adopts a 25mm diameter quartz window with an internal diffuse reflection coating to ensure that the output light Angle conforms to the cosine distribution (Angle response error ≤±2%), meeting the testing requirements of large-area samples (light intensity uniformity within a range of 100mm×100mm ≤±3%).
2. High-precision temperature control and drive system: Stability guarantee from components to the system
The stability of light intensity is directly related to the operating temperature of the equipment and the accuracy of the power supply drive. Through the design of "dual circulation temperature control + constant current and constant voltage drive", Saifan has controlled the long-term stability of light intensity at 0.08%/h. The specific technical solution is as follows:
Technical details of the dual circulation water cooling system
In response to the different heat dissipation requirements of xenon lamps and LED arrays, an independent water-cooling circuit is designed. The core parameters and component selections are as follows:
Loop type
Material of heat exchanger
Pump type
Temperature control accuracy
"Traffic"
Core role
Xenon lamp circuit
Titanium alloy
Magnetic drive pump (Head 5m)
Plus or minus 0.1 ℃
8L/min
Control the temperature of the xenon lamp (operating temperature 80℃±2℃) to avoid light intensity drift
LED array circuit
Aluminum alloy
Centrifugal water pump (Head 3m)
Plus or minus 0.5 ℃
12L/min
Control the temperature of the LED array (operating temperature ≤60℃) to prevent spectral shift
The water cooling system is equipped with a liquid level sensor and a temperature sensor. When the liquid level drops below the threshold or the temperature exceeds the limit, it will automatically trigger an alarm and cut off the power supply of the light source to ensure the safe operation of the equipment.
Performance parameters of constant current and constant voltage drive module
The constant current drive circuit controlled by the imported TI DSP chip (TMS320F28335) has the following core performance indicators:
Output current range: 0-20A, stability ≤±0.01%;
Output voltage range: 0-48V, ripple ≤5mV;
Response speed: ≤10μs (dynamic adjustment for load changes);
Protection functions: Overcurrent (threshold adjustable), overvoltage (48V±5%), and over-temperature (85℃) protection to ensure the long-term stable operation of the light source.
Closed-loop control of light intensity feedback regulation
High-precision silicon photovoltaic cells (model: Hamamatsu S1336-18K) are installed at the light outlet, with a measurement range of 0-2000W/m² and an accuracy of ±0.5%. The light intensity data is collected in real time and fed back to the control system. The PID algorithm (proportional coefficient 1.2, integration time 0.5s, differential time 0.1s) is adopted to dynamically adjust the power of the light source, achieving a light intensity fluctuation of ≤±0.1%/h and solving the problem of large light intensity drift in traditional open-loop control.
3. Intelligent Algorithm Module: Software empowerment from spectral fitting to scene simulation
In response to the diverse lighting environment requirements of different industries, Saifan has developed a dual algorithm module of "spectral calibration + scene simulation", which enhances the flexibility and accuracy of the equipment through software empowerment. The core algorithm technical details are as follows:
The principle of the 5th generation spectral fitting algorithm:
Based on a database of 2 million measured spectra (covering standard light sources such as AM1.5G, AM0, and D65, as well as surface light characteristic data of Mars and the Moon), spectral fitting was carried out using the least square method. The specific steps are as follows:
Collect the original spectral data of the mixed light source (wavelength interval 1nm, range 350nm-1100nm);
Compare with the target spectrum (such as AM1.5G) and calculate the energy deviation of each band;
The power of the xenon lamp and each LED channel is allocated through an algorithm to minimize the deviation (fitting error ≤±0.5%).
Supports user-defined spectral curves (such as 30% enhancement and 50% attenuation for specific bands), and the algorithm response time is ≤1 second.
Engineering Application of Multi-Scenario Simulation Algorithm
It is equipped with 12 preset scene modes such as "Photovoltaic Testing", "Aerospace material Aging", "Photocatalytic reaction", and "plant growth". The parameter Settings for each mode are based on industry standards and actual application requirements.
Photovoltaic test mode: Default AM1.5G spectrum, light intensity 1000W/m², supports automatic IV curve acquisition (sampling interval 10ms);
Aerospace material aging mode: Default AM0 spectrum, light intensity 1367W/m², supports continuous operation for 720 hours (combined with high and low temperature chambers to achieve environmental simulation from -40 ℃ to 60℃).
Plant growth mode: By default, red light (660nm) accounts for 65% and blue light (450nm) accounts for 10%. It supports automatic switching between 16h and 8h photcycles (control accuracy of light quantum flux density PPFD ±5μmol/(m² · s)).
4. Core component selection logic: Balanced design based on reliability and performance
Saifan adheres to the principle of "performance first, reliability guaranteed" in the selection of key components. The selection basis and verification standards for core components are as follows:
Light source component: Xenon lamps are selected from imported brands (Ushio, Osram) and need to pass a 1000-hour continuous operation test (light attenuation rate ≤5%). The LED chips are selected from first-line brands such as Cree and Osram, and they need to pass the high and low temperature cycle test of -40 ℃ to 85℃ (1000 cycles without failure).
Electronic components: DSP chips and constant current drive modules are selected from industrial-grade devices (operating temperature -40 ℃ to 85℃), and capacitors and resistors are chosen from high-temperature resistant and low-drift models (temperature coefficient ≤±100ppm/℃).
Optical components: The condenser and integrating sphere are made of quartz or high borosilicate glass (resistant to ultraviolet aging, with a light transmittance of ≥99%), and the diffuse reflection material is PTFE (resistant to ultraviolet and high temperatures, with a reflectivity of ≥99%).
5. Typical fault investigation and operation and Maintenance Plan
Based on the operation and maintenance data of 1,500 devices, Saifan has summarized the troubleshooting process and solutions for common faults to ensure the long-term stable operation of the equipment
Fault Type 1: Light intensity stability out of tolerance (> ±0.3%/h)
Troubleshooting steps: 1. Check the flow rate of the water-cooling system (≥8L/min) and the temperature (80℃±2℃ for the xenon lamp circuit); 2. Calibrate silicon photovoltaic cells (use standard light sources for accuracy verification); 3. Check the stability of the output current of the constant current drive module (≤±0.01%);
Solution: If the flow rate is insufficient, clean the pump filter screen. If the accuracy of the silicon photovoltaic cell exceeds the tolerance, replace the sensor with a new one. If the drive module malfunctions, replace the DC-DC module.
Fault Type 2: Spectral matching degree decreases (> ±5%)
Troubleshooting steps: 1. Check the usage time of the xenon lamp (if it exceeds 1000 hours, it needs to be replaced); 2. Detect the power of the LED channel (whether there are individual channel failures); 3. Re-run the spectral fitting algorithm;
Solution: Replace the aged xenon lamp; Repair the failed LED channel (replace the driver module or chip); Recalibrate the spectral curve.
Fault Type 3: The device fails to start
Troubleshooting steps: 1. Check the power supply voltage (220V±10% is required); 2. Check the liquid level of the water cooling system (it should be ≥ the lowest mark); 3. Check the emergency stop button and safety interlock (whether they are in the triggered state);
Solution: Stabilize the power supply voltage; Replenish the coolant; Reset the emergency stop button and the safety interlock.
Ii. Compliance of performance indicators with Industry Standards: Data-driven technical verification
The core performance indicators of Saifan solar simulators have all been verified by third-party testing institutions (National Institute of Metrology, China), and fully comply with international standards such as IEC 60904-9 and ASTM E927. The specific indicators are shown in the following table:
Performance parameters
Saifan equipment index value
International standard requirements (IEC 60904-9)
Detection method
Application scenario adaptability
Spectral range
350nm-1100nm
400nm-1100nm (Class A)
Measurement by spectrometer (resolution 0.5nm)
Covering all the needs of photovoltaic, photocatalysis and plant growth
Spectral matching degree (AM1.5G)
Grade A + (≤±2%)
Grade A (≤±5%
Calculate the deviation by comparing with the standard spectrum
The first-level standard for photovoltaic cell efficiency calibration
Light intensity range
100-2000W/m² (continuously adjustable)
500-1500W/m² (Class A)
High-precision silicon photovoltaic cell measurement
Adapt to different light intensity requirements scenarios (such as weak light photocatalysis, strong light aging tests)
Light intensity stability (8h
Plus or minus 0.08% or less
≤±0.5% (Grade A)
Continuously collect light intensity data to calculate fluctuations
Long-term aging tests (such as 720h irradiation of aerospace materials)
Uniformity of light intensity (100mm×100mm
Plus or minus 3% or less
≤±5% (Grade A)
Multi-point sampling method (10×10 grid)
Large-area sample testing (such as 100mm×100mm photovoltaic modules)
Temperature control accuracy
Plus or minus 0.1 ℃
-
Measurement with platinum resistance thermometer (accuracy ±0.05℃)
Extreme environment simulation (-40℃-60℃)
Customize response cycle
≤7 days (Special spectrum)
-
Statistics on the actual project delivery cycle
Urgent mission requirements such as aerospace and deep-sea operations
In addition, the equipment has also passed multiple industry certifications:
Photovoltaic industry: Complies with IEC 61215 and IEC 61730 standards, and can be used for efficiency testing and reliability verification of photovoltaic modules.
Aerospace industry: Passed GJB 150.3-2009 high and low temperature environmental test and GJB 150.9-2009 damp heat environmental test, suitable for space environment simulation of spacecraft materials.
Agricultural industry: It has passed the IP65 dust and water resistance certification and can be used for supplementary lighting tests of plants in damp environments such as greenhouses.
Iii. Industry-customized Solutions and Application Cases: Practical Verification of Technology Implementation
Based on its core technical architecture, Saifan develops customized solutions for the differentiated demands of the four major fields of photovoltaic, aerospace, scientific research, and agriculture, and verifies the effectiveness of the technology through practical applications. Typical cases are as follows:
1. Photovoltaic industry: Perovskite-silicon tandem cell testing solution
A leading photovoltaic enterprise needs to test the efficiency and stability of perovskite-silicon tandem cells, simulate the AM1.5G spectrum, and separately regulate the near-infrared band energy (to verify the absorption efficiency of the silicon substrate layer).
Customized solution
Light source system: On the basis of the basic hybrid light source architecture, an LED supplementary light channel in the 850nm-1100nm band is added (expanding from 32 channels to 64 channels), achieving energy regulation in this band from 0 to 150%.
Test system: Integrated with an IV curve tester (accuracy ±0.1%) and a temperature control platform (temperature control range 25℃-85℃, accuracy ±0.5℃), it supports temperature coefficient testing of battery efficiency.
Data processing: Develop dedicated software to automatically collect IV curves under different near-infrared energies and calculate the changing trend of battery efficiency.
Application effect: Helped customers discover that "when the near-infrared band energy increases by 20%, the efficiency of the tandem battery improves.
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