"2.4m×4.8m super-large photovoltaic module, segmented test splicing error exceeds 7%, certification cycle extends by 3 months", "Whole board new energy vehicle photovoltaic panel test, xenon lamp equipment replaced lamp and stopped production line for 2 days, production capacity loss of one million yuan", "150㎡ scientific research pilot platform, multi-device splicing light uniformity is less than 60% "Experimental data cannot be reused" - In scenarios such as mass production of super-large-sized components, full-board testing of new energy, and large-scale scientific research pilot production, the pain points of "insufficient area, high energy consumption, complex maintenance, and unstable accuracy" have once plunged countless enterprises and research institutions into a predicament of "low efficiency, high cost, and invalid data".
Saifan Optoelectronics has been deeply engaged in optoelectronic technology for 20 years and has specifically launched a large-format 3A-level LED steady-state solar simulator. With the three major advantages of "ultra-wide coverage area + full compliance with IEC 60904-9 3A-level indicators + core LED steady-state technology", it perfectly meets the lighting testing requirements of large area, high frequency and low maintenance. Today, this "high-efficiency and precise light engine" has served over 240 high-end customers worldwide, increasing the testing efficiency of photovoltaic modules by four times, reducing the testing and maintenance costs of the entire panel material by 80%, and achieving a parallelism of over 95% in large-scale scientific research experiments. It has become the "preferred equipment" for large-scale high-efficiency and precise light testing.
1. Mass production of super-large photovoltaic modules: 2.4m×4.8m ultra-large format, 3A-level precision for efficient testing of the entire panel
Mr. Chen, the production and testing supervisor of a leading photovoltaic enterprise, was once extremely troubled by the mass production testing of super-large modules: "When we mass-produce super-large photovoltaic modules of 2.4m×4.8m, the traditional xenon lamp simulator has a size of only 1m×1m and needs to be tested in 12 sections. It takes 48 hours to test one module. The production line is stuck in the testing stage, and the daily output is less than 50 units." What's more troublesome is that the light intensity of the xenon lamp equipment fluctuates by more than 3%. To replace the lamp, the production line has to be shut down for two days. The annual loss from lamp replacement amounts to 800,000 yuan. The deviation of test data also leads to a customer return rate of over 10%."
After the introduction of the Saifan large-format 3A-level LED steady-state simulator, the production efficiency has witnessed a "qualitative leap". The core highlight of this equipment 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 has been compressed from 48 hours to 12 hours, with efficiency increased by four times. The daily output of a single production line has soared from 50 pieces to 200 pieces, and the annual production capacity has increased by more than 50,000 pieces. More importantly, all indicators have reached the 3A-level standard: Spectral matching degree A + grade (0.875-1.125), light intensity uniformity A grade (≤±3%), time stability A grade (≤±0.2%/h), fully meeting the IEC 60904-9 certification standard. "Now the test data passes the customer acceptance at one time, and the return rate has dropped from 10% to 0.5%. The product delivery cycle has been shortened by three months.
The advantages of the LED strong core are fully demonstrated: 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 "ultraviolet attenuation". 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 market demands of different regions around the world. Engineer Chen did a detailed calculation: "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, with an annual electricity cost reduction of 240,000 yuan. The lifespan of the LED light source is 100,000 hours (calculated at 8 hours a day, it can be used for 34 years), and there is no need to replace the lamp throughout its lifetime. It generates 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, low maintenance and zero line stoppage
Mr. Lin, the materials research and development manager of a certain new energy vehicle enterprise, once encountered a "maintenance predicament" during the testing of entire vehicle-mounted photovoltaic panels: "When we tested the entire 1.8m×2.5m vehicle-mounted photovoltaic panel, the light intensity of the traditional xenon lamp equipment fluctuated by 5%, the data drift of the continuous 720-hour aging test exceeded 4%, and the deviation of the material life assessment reached 2 years." What's even more troublesome is that the lifespan of the xenon lamp is only 1,000 hours. During the testing process, the lamps are frequently replaced, with an annual cost of replacing them exceeding 500,000 yuan. This has also led to more than ten production line shutdowns, resulting in a loss of over one million yuan in production capacity."
Saifan's 3A-level LED steady-state solution precisely addresses the dual pain points of "precision + maintenance". The equipment is customized with a super-large format of 1.8m×3.6m, featuring 288 groups of high-consistency LED arrays and an intelligent light homogenization system. The uniformity of the light spot is ≤±2.5%, and the temperature difference of the entire board is ≤±1℃, perfectly recreating the real lighting conditions. Core performance is more hardcore: The LED steady-state driving technology reduces the light intensity stability to ±0.05%/8h. After continuous 1000-hour testing, the light intensity drift is ≤±0.8%, far exceeding the industry's 3A-level standard of ±0.3%/h. The spectral matching degree is always stable at the A + level, ensuring that the material testing mechanism is consistent with that outdoors, and the data repeatability is ≤±0.5%.
"Now, the entire board test can be completed in one go without the need to replace the lights. There is no line interruption throughout the year, and the maintenance cost has dropped from 500,000 to 100,000, a reduction of 80%." " 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 LED equipment cost 12 million yuan, with a delivery period of six months. The customized model of Saifan saves 6 million yuan, is delivered within 45 days, and also offers on-site debugging and training. The precision and cost performance of domestic LED equipment have completely broken the monopoly of imports.
Iii. Large-scale scientific Research pilot projects: 150 square meters coverage + 96% uniformity, precise control facilitates technology transfer
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 xenon lamp 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." What's more troublesome is that the energy of the xenon lamp in the ultraviolet band is not adjustable, which cannot match the demands of different catalytic reactions, and the industrialization process of the project has been repeatedly postponed.
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 +. It can simulate the catalytic efficiency under different lighting conditions and even supports custom spectral curves to meet personalized research needs.
"Now, the conversion rate deviation of the same batch of experiments has dropped from 20% to 1.5%. Last year alone, four top journal papers were published and five national patents were applied for. The project has been successfully industrialized." " 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. It can also be linked with temperature, humidity and pressure 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 xenon lamp devices is 180,000 yuan, while that for 1 Saifan LED device is only 25,000 yuan, saving 155,000 yuan in electricity annually and completely saying goodbye to the trouble of "frequent lamp replacement and repeated calibration".
Iv. Core Technology Unveiling: Why Can 3A-level LED Steady-State Balance "Large Format" and "High Efficiency and 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. The LED array's collaborative control ensures consistent accuracy across the entire spectrum.
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 "temperature drift" problems of traditional equipment, 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%.
Low energy consumption and long life design: It adopts imported high-power LED chips, with a photoelectric conversion efficiency of 35%, saving 80% more electricity than traditional xenon lamp equipment. The LED light source has a lifespan of 100,000 hours and does not need to be replaced throughout its lifetime, reducing maintenance costs by 80%.
Five. Not Only equipment, but also a "large-area high-efficiency lighting testing partner"
Saifan Optoelectronics is well aware that high-end LED 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 based on the height of the customer's laboratory and the layout of the production line to adapt to diverse scenarios such as photovoltaic, new energy, and scientific research.
Ultra-fast response service: 9 regional technical centers across the country, 100% commonly used parts in stock, promise 7× 24-hour response, on-site repair within 24 hours - During the peak production period of a certain photovoltaic enterprise, equipment failure occurred, engineers arrived at the scene within 4 hours and repaired it within 1 hour, without delaying the production of the same day.
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. Core components (LED driver, uniform light system) are guaranteed for 5 years to ensure the long-term validity of test data.
Vi. Future Outlook: Wider format, smarter and more efficient
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 aircraft model to meet the testing requirements of 5m×6m giant photovoltaic modules and the entire cabin of new energy.
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 an "LED Lighting Test Cloud Platform" to achieve remote collaboration among multiple devices, real-time data upload and analysis, support AI-assisted optimization of experimental plans, and further enhance testing efficiency.
From the mass production testing of super-large photovoltaic modules to the precise assessment of new energy whole board materials, and then to the efficient advancement of large-scale scientific research pilot tests, with 20 years of technological accumulation, Saifan Optoelectronics has made "large format + 3A precision + LED strong core" artificial sunlight the "core support" for efficient and precise lighting testing. If your work is plagued by "small size, high energy consumption, complex maintenance and unstable precision", this LED lighting equipment that sets a new industry benchmark might just be the key for you to break through the bottleneck.
Link Microblog
