"3m×5m giant photovoltaic module certification, the splicing error in the segmented test exceeded 8%, and the international certification was not passed." "Under extreme high-temperature conditions, the light attenuation of LED equipment is severe, and the aging test of the entire board of aerospace materials is interrupted." "Under the demand for strong ultraviolet irradiation, the energy of traditional equipment is insufficient. The "25% deviation in the pilot-scale efficiency of photocatalysis" - in the certification of super-large components, material testing in extreme environments, and strong ultraviolet research scenarios, the pain points of "insufficient area, poor anti-fabrication, and incomplete full-spectrum coverage" have once plunged countless enterprises and research institutions into the predicament of "data failure and project delay".
Saifan Optoelectronics has been deeply engaged in optoelectronic technology for 20 years and has specifically launched a large-format 3A-level xenon lamp steady-state solar simulator. With the three core advantages of "ultra-wide coverage area + full compliance with IEC 60904-9 3A-level indicators + xenon lamp steady-state strong core", it perfectly meets the strict testing requirements in large areas, strong irradiation and extreme environments. Today, this "Light beast" has served over 230 high-end customers worldwide, increasing the certification efficiency of giant photovoltaic modules by five times, achieving a 100% pass rate in extreme environment material tests, and having a parallelism of over 96% in strong ultraviolet scientific research experiments. It has become the "hardcore choice" for large-scale and strict light tests.
1. Giant Photovoltaic Module Certification: 3m×5m ultra-large format, 3A-level precision, passing international certification in one go
Mr. Wang, the certification director of a multinational photovoltaic enterprise, was once extremely troubled by the certification of giant modules. We developed a 3m×5m super-large photovoltaic module. The traditional small spot simulator had to test it in 15 sections, which took three days. The total error after assembly reached 8%. When it was sent to TUV Rheinland for certification, it was directly rejected. The plan to enter the European market for the product was delayed by six months. What is even more troublesome is that some markets require that tests must be conducted using xenon lamp simulators (the spectrum of xenon lamps is closer to that of natural sunlight). Traditional xenon lamp equipment has a small area and poor stability, which simply cannot meet the demands.
After the introduction of the Saifan large-format 3A-level xenon lamp steady-state simulator, the certification problem was easily solved. The core highlight of this device is its 3m×5m ultra-large format - no need for segmentation, it can cover the entire board of giant components at one time. The testing time has been compressed from 72 hours to 14 hours, with efficiency increased by five times and the cost of single-component certification reduced by 65%. 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 (≤±0.2%/h). It fully meets the international certification standards such as IEC 60904-9, TUV, UL, etc. "Now the sample submission for certification is passed in one go." International testing institutions all recognize the data of Saifan xenon lamp equipment, and the products have successfully entered the European and Australian markets.
The strong core advantages of xenon lamps are fully demonstrated: It adopts imported 1500W ultra-high pressure short-arc xenon lamps, continuously covering the entire wavelength range from 300nm to 1100nm. Especially in the 280-400nm ultraviolet band, the energy restoration accuracy exceeds 97%, far superior to LED devices, perfectly simulating the full-spectrum characteristics of natural sunlight. 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/D65, meeting the certification requirements of different regions around the world. Engineer Wang did the math: "Previously, the annual electricity cost for 10 small-spot xenon lamp devices was 400,000 yuan, and the loss from lamp replacement and line shutdown was 1.2 million yuan." Now, one large format xenon lamp from Saifan can save 60% of electricity, with an annual electricity cost reduction of 240,000 yuan. The xenon lamp has a lifespan of 1,000 hours (supporting quick replacement, with only 15 minutes for lamp replacement), and has created an output value of over 30 million yuan in more than a year.
Ii. Extreme Environment Material Testing: 2.5m×4m format +±0.1% stability, no interruption in testing under high temperature and strong light
Liu Gong, a materials researcher at a certain aerospace science and technology group, once encountered a "fatal interruption" in extreme environment testing: "When we test the entire plate material of a 2.5m×3m spacecraft, we need to conduct a 1000-hour aging test at a high temperature of 60℃ and under a strong light of 1500W/m²." The traditional LED equipment has a light attenuation of over 15% at high temperatures. The test was forced to be interrupted after 300 hours, and the 2 million yuan of R&D cost invested in the early stage was wasted. What is even more dangerous is that the ultraviolet band energy of LED equipment is insufficient, making it impossible to simulate the strong ultraviolet irradiation environment in space. Misjudging the anti-aging performance of materials may affect the safety of spacecraft in orbit.
Saifan's 3A-level xenon lamp steady-state solution precisely addresses the pain points in extreme environments. The equipment is customized with a 2.5m×4m ultra-large format, featuring 8 sets of high-power xenon lamp arrays and a dual-circulation water cooling system. It operates stably in a wide temperature range of -40 ℃ to 60℃. Under 60℃ high temperature, the light intensity drift during continuous 1000 hours of testing is ≤±0.8%, which is far superior to the industry's 3A-level standard of ±0.3%/h. The uniformity of the light spot is ≤±2.8%, the irradiation dose of the entire board material is consistent, and the temperature difference is ≤±1.5℃, perfectly reproducing extreme light conditions such as space and deserts.
Core performance is more hardcore: The xenon lamp steady-state drive technology reduces the light intensity stability to ±0.1%/8h, and the repeatability of continuous 1000-hour test data is ≤±0.6%. It covers the full wavelength range of 300nm to 1100nm, with an irradiance of up to 500W/m² in the ultraviolet band, meeting the requirements for strong ultraviolet aging tests of spacecraft materials, weather-resistant coatings, etc. "Now, extreme environment tests can be completed in one go, and the data is directly used for spacecraft design, eliminating the need for repeated restarts." " Mr. Liu introduced that with the help of the "strong irradiation simulation" function of the equipment, the team successfully developed a new type of anti-ultraviolet whole plate material, extending its in-orbit service life from 8 years to 15 years. Previously, importing 3A-level xenon lamp equipment cost 15 million yuan, with a delivery period of 8 months. The custom-made model from Saifan saves 7 million yuan and is delivered within 60 days. It also offers on-site calibration services in high-temperature environments. The durability and precision of domestic xenon lamp equipment have completely broken the monopoly of imports.
Iii. Strong Ultraviolet Research Pilot Test: 200㎡ coverage + 96% uniformity, zero deviation in photocatalytic efficiency test
Professor Zhang from the School of Chemical Engineering of a certain university was once worried about the lighting problem of a 200-square-meter strong ultraviolet photocatalytic pilot platform: "The ultraviolet energy of the traditional supplementary lighting equipment is insufficient. 40 units need to be connected together, and the uniformity of lighting is less than 55%. The catalytic efficiency deviation of the same batch of experiments exceeds 25%, and no top journal paper has been published in four years." More importantly, the LED equipment is unable to provide high-intensity ultraviolet irradiation, making it difficult to meet the scale-up testing requirements in the pilot stage. As a result, the industrialization process of the project has been repeatedly postponed.
Saifan's custom-made 3A-level xenon lamp steady-state simulator for scientific research has immediately broken the deadlock. The equipment adopts a "high-power xenon lamp array + distributed uniform light design", with a single unit capable of covering a 200-square-meter pilot platform. The light uniformity reaches 96%, and the parallelism of experimental data has been increased from 55% to 96%. It covers the full wavelength range from 300nm to 1100nm. The ultraviolet (300-400nm), visible (400-760nm), and near-infrared (760-1100nm) bands can be independently adjusted with 1% accuracy. The ultraviolet irradiance can reach up to 800W/m², perfectly matching the strong ultraviolet requirements of different photocatalytic reactions.
Now, the catalytic efficiency deviation of the same batch of experiments has dropped from 25% to 1.8%. Last year alone, five top-tier journal papers were published and six national patents were applied for. The project has been successfully industrialized. Professor Zhang particularly praised the "intelligent light control system" of the equipment: "Through the upper computer software, the ultraviolet light intensity gradient and spectral combination can be set. It can also be linked with the temperature and pressure sensors of the reaction vessel to achieve closed-loop control. Experiments that previously required six people to operate can now be completed by one person." More surprising in energy consumption and maintenance: The annual electricity cost for 40 traditional devices is 250,000 yuan, while for 1 Saifan xenon lamp device, it is only 40,000 yuan, saving 210,000 yuan in electricity costs annually. Xenon lamps support quick replacement, reducing maintenance workload by 80% and completely saying goodbye to the trouble of "frequent lamp replacement and repeated calibration".
Iv. Core Technology Unveiling: Why Can 3A-level Xenon Lamp Stable State Balance "Large Format" and "Harsh Scene Adaptation"?
The core competitiveness of Saifan's large-format 3A-level xenon lamp steady-state solar simulator stems from four breakthrough technologies in the industry:
3A-level full-index compliance architecture: Adopting "high-consistency xenon lamp 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. The xenon lamp array's collaborative control avoids "the attenuation of a single lamp affecting the overall accuracy".
Xenon lamp steady-state drive technology: Independently developed constant current and constant voltage drive module, current stability ≤±0.01%, supports independent control of 96 groups of xenon lamps, combined with a dual-circulation water cooling system (xenon lamp circuit temperature control accuracy ±0.1℃), avoids the "pulse fluctuation" and "temperature drift" problems of traditional xenon lamps, and the light intensity stability reaches ±0.1%/8h.
Ultra-large format uniform light system: Equipped with a 3m×6m ultra-large size integrating sphere (PTFE coating with a reflectivity of ≥99.5%) + aspheric wide-angle condenser. After 150,000 optical simulations, it achieves "no divergence of large light spots and no distortion at the edges", with a 3m×5m format uniformity of ≤±3%.
Extreme environment adaptation design The body is made of 6061-T6 military-grade aluminum alloy, with an airtight seal and dust-proof and water-proof design (protection level IP65). It is equipped with a 1000Hz high-sensitivity dual sensor for light intensity and spectrum, and is combined with an AI adaptive calibration algorithm to compensate for errors caused by temperature and voltage fluctuations in real time, ensuring stable long-term operation accuracy in extreme environments.
Five. Not Only equipment, but also a "Partner for Harsh scene lighting testing"
Saifan Optoelectronics is well aware that high-end xenon lamp 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. For extreme environmental requirements, anti-sand, moisture-proof, and radiation-proof modifications can be added to adapt to special scenarios such as aerospace and desert scientific research.
Ultra-fast response service There are 9 regional technical centers across the country, with 100% of commonly used spare parts (including xenon lamps and core components of water cooling systems) in stock. We promise a 7× 24-hour response and on-site maintenance within 24 hours. For instance, a certain photovoltaic enterprise experienced equipment failure just before its international certification. Engineers arrived at the scene within 3 hours and completed the replacement and calibration of the xenon lamp within 1 hour, without delaying the certification progress.
Authoritative calibration guarantee: The equipment comes with a traceable NIST calibration report, supports CNAS laboratory certification, and offers two free on-site calibration services per year (including special calibration in extreme environments). Core components (xenon lamp drive, water cooling system) are guaranteed for 5 years to ensure the long-term validity of test data.
Vi. Future Outlook: Wider format, better compatibility
With the upgrading demands for giant photovoltaic modules, extreme environment materials, and strong ultraviolet research, Saifan is still continuously upgrading its technology
Develop a 4m×6m ultra-large format model to meet the testing requirements of 6m×8m giant photovoltaic modules and the entire spacecraft cabin.
Optimize the lifespan and energy efficiency of xenon lamps, and introduce a 2000-hour long-life xenon lamp module to further reduce usage costs.
Build a "xenon Lamp Illumination Test Cloud Platform" to achieve remote collaboration among multiple devices, real-time data upload and analysis, and support AI-assisted optimization of extreme environment experiment plans.
From the international certification of giant photovoltaic modules to material testing in extreme environments and then to the scientific research and pilot production of strong ultraviolet rays, Saifan Optoelectronics has, with 20 years of technological accumulation, made artificial sunlight featuring "large format + 3A precision + xenon lamp strong core" the "core support" for harsh lighting scenarios. If your work is plagued by "small size, poor durability and incomplete full-spectrum coverage", this xenon lamp lighting equipment that sets a new industry benchmark might just be the key for you to break through the bottleneck.
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