"2m×4m super-large photovoltaic modules, segmented test splicing error exceeds 7%, certification data is not recognized" "Whole panel vehicle-mounted photovoltaic panel aging test, light intensity fluctuation 5%, material life assessment deviation 3 years" "150㎡ scientific research pilot platform, multiple devices spliced light, uniformity less than 60% "Poor experimental repeatability" - In scenarios such as the certification of super-large-sized photovoltaic modules, the testing of full-board new energy materials, and large-scale scientific research pilot tests, the pain points of "insufficient size, inadequate precision, and poor stability" have once plunged countless enterprises and research institutions into the predicament of "invalid data and cost waste".
Saifan Optoelectronics has been deeply engaged in optoelectronic technology for 20 years and has launched a large-format 3A-level LED steady-state solar simulator. With the three core advantages of "ultra-wide coverage area + full compliance with IEC 60904-9 3A-level indicators + LED steady-state technology", it has solved the problems of accuracy and efficiency in large-area light testing at one time. Today, this "lighting giant" has served over 220 high-end customers worldwide, increasing the certification efficiency of photovoltaic modules by four times, achieving a 100% pass rate for the test data of the entire panel material, and having a parallelism of over 95% in large-scale scientific research experiments. It has become the "preferred equipment" for large-scale high-precision lighting tests.
1. Photovoltaic Module Certification: 2.4m×4.8m ultra-large format, 3A-level precision, one-time certification
Mr. Chen, a certified engineer at a leading photovoltaic enterprise, was once worried about the certification of super-large modules. We developed a super-large photovoltaic module of 2.4m×4.8m. The traditional simulator has a size of only 1m×1m and needs to be tested in 12 sections. This not only took two days but also led to a total error of 7% after the sections were spliced together. When it was sent to a third party for certification, it was directly rejected, delaying the product's market launch by three months. What's more troublesome is that the light intensity of traditional xenon lamp equipment fluctuates greatly, and the data drift during the testing process exceeds 3%. Repeated testing leads to a sharp increase in certification costs.
After the introduction of the Saifan large-format 3A-level LED steady-state simulator, the certification process has been completely "accelerated and efficient". The core highlight of this device is its 2.4m×4.8m ultra-large format - no need for segmentation, it can cover the entire board assembly at one time. The testing time is compressed from 48 hours to 12 hours, the efficiency is increased by 4 times, and the certification cost of a single component is reduced by 60%. More importantly, all indicators have reached the 3A-level standard: The spectral matching degree is A + grade (0.875-1.125), the light intensity uniformity is A grade (≤±3%), and the time stability is A grade (≤±0.3%/h). It fully meets the IEC 60904-9 certification standard. "Now, the sample submission certification is passed in one go, and the data of the Saifan equipment is recognized by all third-party testing institutions. The product launch cycle has been shortened by three months.
The LED steady-state technology has more advantages: It adopts imported high-power LED arrays, continuously covering the entire wavelength range from 350nm to 1100nm. The energy restoration accuracy in the near-infrared region exceeds 98%, eliminating the pain points of xenon lamps such as "spectral drift" and "lamp replacement shutdown". The light intensity of the equipment can be continuously adjusted from 100 to 2000W/m², and it supports one-click switching of multiple standard spectra such as AM1.5G/AM0, meeting the certification requirements of different regions around the world. Engineer Chen did the math: "Previously, the annual electricity cost for 8 small-spot xenon lamp devices was 300,000 yuan, and the loss due to lamp replacement and line shutdown was 800,000 yuan." Now, one set of Saifan LED equipment can save 80% of electricity, saving 240,000 yuan in electricity fees annually. The LED light source does not need to be replaced for 100,000 hours, and it has created an output value of over 20 million yuan in more than a year.
Ii. New energy whole board Test: 1.8m×3.6m format + 0.05% stability, zero deviation in material life assessment
Lin, the material research and development supervisor of a certain new energy vehicle enterprise, once encountered a "fatal error" in the test of the entire vehicle-mounted photovoltaic panel: We tested 1.8m×2.5m vehicle-mounted photovoltaic panels. The light intensity of traditional equipment fluctuated by 5%. After 720 consecutive hours of aging tests, the material life assessment deviation reached 3 years, resulting in premature aging of the first batch of panels installed in vehicles. The recall loss exceeded 5 million yuan. What is more challenging is that the small light spot splicing and irradiation cause the temperature difference of the entire board to exceed 8℃, making it impossible to simulate the performance under real working conditions.
Saifan's 3A-level LED steady-state solution precisely addresses this pain point. The equipment is customized with a super-large format of 1.8m×3.6m, featuring 288 groups of high-power leds for coordinated light emission. Optimized by ZEMAX optical simulation, the uniformity of the light spot is ≤±2.5%, and the temperature difference across the entire board is ≤±1℃, perfectly regenerating the real lighting conditions. Core performance is more hardcore: Time stability is as low as ±0.05%/8h, and the light intensity drift during continuous 1000-hour testing is ≤±0.8%, far exceeding the industry 3A-level standard of ±0.3%/h. The spectral matching degree remains consistently stable at the A + level, ensuring that the material aging mechanism is consistent with that outdoors.
"Now, the repeatability of the entire board test data is ≤±0.5%, the material life assessment error has been reduced to 0.2 years, and no premature aging problem has occurred after loading." " Engineer Lin introduced that with the help of the "dynamic light intensity simulation" function of the equipment, the team successfully developed a new type of anti-aging coating, extending the lifespan of the vehicle-mounted photovoltaic panels from 5 years to 8 years. Previously, importing 3A-level equipment cost 12 million yuan, with a delivery period of six months. The custom-made model from Saifan saves 6 million yuan and is delivered within 45 days. It also offers on-site calibration services. The precision and service of domestic equipment have completely broken the monopoly of imports.
Iii. Large-scale scientific research pilot tests: 150 square meters coverage + 96% uniformity, experimental data parallelism over 95%
Professor Li from a research institute affiliated with the Chinese Academy of Sciences was once troubled by the lighting problem of a 150-square-meter photocatalytic pilot platform: "Traditional supplementary lighting equipment requires 30 units to be spliced together, with a light uniformity of less than 60%. The deviation of experimental data in the same batch exceeds 20%, and no top-tier journal paper has been published in three years." More importantly, the spectrum of small-spot equipment is single, and it is impossible to precisely control the proportion of ultraviolet and near-infrared bands, making it difficult to meet the demands of different catalytic reactions.
Saifan's custom-made 3A-level LED steady-state simulator for scientific research has immediately broken the deadlock. The equipment adopts a "high-power LED array + distributed uniform light design", with a single unit capable of covering a 150-square-meter pilot platform. The light uniformity reaches 96%, and the parallelism of experimental data has been increased from 60% to 95%. It supports independent adjustment with 1% accuracy in the ultraviolet (350-400nm), visible (400-760nm), and near-infrared (760-1100nm) bands, with A spectral matching degree of A +, and can simulate the catalytic efficiency under different lighting conditions.
Now, the conversion rate deviation of the same batch of experiments has dropped from 20% to 1.5%. Last year alone, four top-tier journal papers were published and five national patents were applied for. Professor Li particularly praised the "intelligent light control system" of the equipment: "Through the upper computer software, the light intensity gradient and spectral combination can be set, and it can also be linked with temperature and humidity sensors to achieve closed-loop control. Experiments that previously required five people to operate can now be completed by one person." The energy consumption is even more surprising: The annual electricity cost for 30 traditional devices is 180,000 yuan, while that for 1 Saifan device is only 25,000 yuan, saving 155,000 yuan in electricity costs annually and reducing the maintenance workload by 90%.
Iv. Core Technology Unveiling: Why Can 3A-level LED Steady-State Balance "Large Format" and "High Precision"?
The core competitiveness of Saifan's large-format 3A-level LED steady-state solar simulator stems from four breakthrough technologies in the industry:
3A-level full index compliance architecture: Adopting "high consistency LED array + 6th generation spectral fitting algorithm", the spectral matching degree (A+), uniformity (A), and stability (A) all indicators meet the IEC 60904-9 3A-level standard, and there is no attenuation during long-term operation.
LED steady-state driving technology: Independently developed constant current driving module, current stability ≤±0.01%, supports independent control of 288 groups of leds, avoids the "pulse fluctuation" and "spectral drift" problems of traditional xenon lamps, and the light intensity stability reaches ±0.05%/8h.
Ultra-large format uniform light system: Equipped with a 2m×5m ultra-large size integrating sphere (PTFE coating with a reflectivity of ≥99.5%) + aspheric wide-angle condenser. After 100,000 optical simulations, it achieves "no divergence of large light spots and no distortion at the edges", with a 2.4m×4.8m format uniformity of ≤±3%.
Intelligent closed-loop control: Equipped with 1000Hz high-sensitivity light intensity/spectrum dual sensors, combined with AI adaptive calibration algorithms, it can compensate for errors caused by voltage fluctuations and environmental temperature changes in real time, ensuring stable long-term operation accuracy.
Five. Not Only equipment, but also a "large-area light testing partner"
Saifan Optoelectronics is well aware that high-end testing equipment requires full-cycle support
Full-dimensional customization: The format size (1m×1m to 3m×6m), spectral type (AM1.5G/AM0/D65), and installation method (floor-standing/suspended/mobile) can all be customized. Even the equipment structure can be optimized according to the height of the customer's laboratory and the layout of the production line.
Ultra-fast response service: With 9 regional technical centers across the country, 100% commonly used spare parts are in stock. We promise a 7× 24-hour response and on-site repair within 24 hours. For instance, a photovoltaic enterprise experienced equipment failure just before its certification. Engineers arrived at the scene within 4 hours and repaired it within 1 hour, without delaying the certification progress.
Authoritative calibration guarantee: The equipment comes with a traceable NIST calibration report, supports CNAS laboratory certification, offers free on-site calibration services twice a year, and core components are guaranteed for 5 years to ensure the long-term validity of test data.
Vi. Future Outlook: Wider format, more precise control
With the development of photovoltaic modules and new energy materials towards "larger sizes and higher efficiency", Saifan is still continuously upgrading its technology
Develop a 3m×6m ultra-large format model to meet the testing requirements of 5m×6m giant photovoltaic modules and the entire spacecraft cabin.
Integrating quantum dot light source technology, the spectral range is expanded to 200nm-2500nm, meeting the requirements of deep ultraviolet photocatalysis and mid-infrared material testing.
Build a "Lighting Test Cloud Platform" to achieve remote collaboration among multiple devices, real-time data upload and analysis, and support AI-assisted optimization of experimental plans.
From the certification of super-large photovoltaic modules to the testing of new energy whole board materials, and then to large-scale scientific research pilot production, with 20 years of technological accumulation, Saifan Optoelectronics has made "large format + 3A precision + LED stable state" artificial sunlight the "core support" for high-end manufacturing and scientific research innovation. If your work is being troubled by "small format, poor precision and insufficient stability", this lighting equipment that sets a new industry benchmark might just be the key for you to break through the bottleneck.
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