"Long-term reliability test of photovoltaic modules, light intensity drift exceeds 5%, 2000-hour aging data distortion" "Material weather resistance test, spectral matching degree is less than 85%, outdoor actual performance deviates from test results by 20%" "Scientific research pilot platform, poor light uniformity The repeatability of the same batch of experimental data is only 60% - in scenarios such as photovoltaic module certification, material weather resistance testing, and scientific research experiments, the pain points of "insufficient long-term stability, inaccurate spectral replication, and poor uniformity" have once plunged countless enterprises and research institutions into the predicament of "invalid data, project delays, and high costs".
Saifan Optoelectronics has been deeply engaged in optoelectronic technology for 20 years and has launched a 3A-level steady-state solar simulator. With the three core advantages of "IEC 60904-9 3A full index compliance + long-term steady-state operation + multi-scenario adaptation", it perfectly meets the strict requirements of long-term aging, precise detection, scientific research experiments, etc. Today, this "benchmark equipment for light testing" has served over 280 high-end customers worldwide, raising the pass rate of photovoltaic module testing to 99.6%, ensuring that the weather resistance test data of materials is consistent with outdoor standards by over 95%, and achieving a repeatability of scientific research experiments of 98%. It has become the "core support" for all-scenario light testing.
1. Photovoltaic module certification Test: 3A full indicators + long-term stability, passing international certification in one go
Mr. Wang, the certification manager of a leading photovoltaic enterprise, was once worried about the international certification of components We are going to conduct a 2,000-hour long-term reliability test for TUV and UL certifications. After running the traditional simulator for 1,000 hours, the light intensity drift exceeded 5%, and the spectral matching degree dropped to grade B. The test data was rejected by the certification body, and the plan for our product to enter the European and American markets was postponed by 8 months. What's more troublesome is that traditional equipment has a small size. Large-sized components of 182mm and 210mm need to be tested in sections, with a splicing error exceeding 3%, which further affects the certification pass rate.
After the introduction of the Saifan 3A-level steady-state solar simulator, the certification problem was easily solved. The core highlight of this device is that it continuously meets all 3A indicators - spectral matching degree A + level (0.875-1.125), light intensity uniformity A level (≤±3%), time stability A level (≤±0.2%/h). After continuous operation for 2000 hours, the light intensity drift is ≤±1%, and the spectral matching degree remains at ≥97%. It fully complies with international certification standards such as IEC 60904-9, TUV and UL. Equipped with a 2.4m×3.6m super-large coverage area, it can cover 210mm large-sized components at one time without the need for segmented testing. The splicing error is zero, and the test data passes the certification body's review in one go.
"Now the component certification cycle has been shortened from six months to two months, smoothly entering the markets of Europe, America and Southeast Asia, with an annual new revenue of over 400 million yuan." " Engineer Wang introduced that 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. The built-in intelligent calibration system automatically calibrates the light intensity and spectrum every 200 hours without manual intervention, ensuring long-term stable test data. Previously, importing 3A-level steady-state equipment cost 10 million yuan, with a delivery period of six months. The customized model from Saifan saves 5 million yuan, with delivery within 45 days. It also offers specialized technical support for certification. The precision and cost-effectiveness of domestic equipment have completely broken the monopoly of imports.
Ii. Material weathering and aging test: Precise spectroscopy + uniform irradiation, test data consistency with outdoor standards exceeds 95%
Mr. Li, the materials research and development manager of a certain automotive OEM factory, once encountered a "fatal deviation" in material testing: We tested the weather resistance of automotive exterior materials. The spectral matching degree of traditional simulators was less than 85%, especially the energy deviation in the ultraviolet band exceeded 30%. As a result, the lifespan of the materials tested in the laboratory was only 8 years, but they cracked and discolored just 3 years after being actually installed in vehicles, causing recall losses of over 12 million yuan. What is even more troublesome is that the irradiation uniformity of traditional equipment is poor (≤±8%), and the deviation of test data for the same batch of materials exceeds 20%, making it impossible to screen the optimal material solution.
The "precise replication" feature of the Saifan 3A-level steady-state solar simulator perfectly resolves this pain point. The equipment adopts imported high-power xenon lamp arrays and the 7th generation spectral fitting algorithm, covering the full wavelength range of 300nm to 1100nm. The matching degree with natural sunlight spectra is ≥98%, and the energy restoration accuracy in the ultraviolet (300-400nm), visible (400-760nm), and near-infrared (760-1100nm) bands exceeds 97%. Accurately reproduce the real outdoor lighting conditions. When paired with a distributed uniform light system, the irradiation uniformity is ≤±2.5%, the temperature difference of the entire board material is ≤±1℃, and the deviation of the test data of the same batch is ≤1.5%.
"Currently, the weather resistance test data of the materials is over 95% consistent with the actual outdoor usage. The in-orbit lifespan of the newly developed exterior materials has been extended from 5 years to 10 years, and no recall issues have occurred again." " Engineer Li introduced that the equipment supports long-term continuous operation (with no downtime limit), can complete over 5,000 hours of extreme aging tests, and in combination with high and low temperature and humidity environmental chambers, it realizes a closed-loop control of "light - temperature and humidity", comprehensively simulating complex outdoor climate conditions. Previously, the annual electricity cost for eight traditional devices was 400,000 yuan, and the maintenance cost was 250,000 yuan. Now, one Saifan Steady-state device can achieve full-scenario testing, saving 320,000 yuan in electricity costs annually, reducing maintenance costs to 50,000 yuan, and also saving 70% of laboratory space."
Iii. Research Experiments and Pilot Production: Flexible regulation + high repeatability, facilitating the output of top-tier journal achievements
Professor Zhang from the School of Chemical Engineering of a certain university was once worried about photocatalytic research experiments: "We are studying photocatalytic degradation of pollutants. The light intensity of traditional simulators fluctuates greatly (≥±3%/h), the uniformity of light is less than 60%, and the degradation efficiency deviation of the same batch of experiments exceeds 25%. We haven't published a single top journal paper in five years." More importantly, traditional equipment has fixed spectra and unadjustable parameters, which cannot match the specific lighting requirements of different catalytic reactions. The amplification test data from the pilot stage cannot be reused.
The research customization version of Saifan's 3A-level steady-state solar simulator has immediately broken the deadlock. The equipment supports continuous adjustment of light intensity with a precision of 1%, and the spectrum can be fine-tuned according to experimental requirements (independent control of ultraviolet, visible, and near-infrared bands), making it suitable for diverse research scenarios such as photocatalysis, photoelectric conversion, and plant cultivation. A single unit can cover a 150-square-meter pilot platform, with a light uniformity of 96%. The repeatability of experimental data has been increased from 60% to 98%, and the deviation of the same batch of experiments is ≤1.2%.
"Now our research on photocatalytic degradation efficiency has made a breakthrough. Last year, we published five top-tier journal papers and applied for eight national patents. The project has been successfully industrialized, with an annual additional output value of over 80 million yuan." " Professor Zhang particularly praised the intelligent control system of the equipment: "Through the upper computer software, the light parameters and test duration can be set. It can also be seamlessly linked with the reaction vessel and detector, automatically recording experimental data and generating curves. Experiments that previously required six people to operate can now be completed by one person." The energy consumption is even more surprising: The annual electricity cost for 40 traditional small light spot devices is 350,000 yuan, while for 1 Saifan steady-state device, it is only 45,000 yuan, saving 305,000 yuan in electricity costs annually and completely saying goodbye to the trouble of "multiple devices splicing and repeated calibration".
Iv. Core Technology Revelation: Why Can It Balance "3A Precision" and "Long-Term Stability"?
The core competitiveness of Saifan's 3A-level steady-state solar simulator stems from four breakthrough technologies:
3A All-Index Compliance Architecture: It adopts "high consistency light source array + 7th generation spectral fitting algorithm", and is equipped with A multi-standard spectral database. The spectral matching degree (A+), uniformity (A), and stability (A) all indicators continuously meet the standards, satisfying international standards such as IEC 60904-9 and ASTM G155.
Steady-state drive control technology: Independently developed constant current and constant voltage drive module, current stability ≤±0.01%, combined with a dual-circulation water cooling system (temperature control accuracy ±0.1℃), it avoids the problems of "temperature drift" and "light intensity fluctuation" of traditional equipment, and the long-term operation stability reaches ±0.2%/h.
Ultra-large beam uniform light system: Equipped with a 3.0m×4.0m ultra-large size integrating sphere (PTFE coating with a reflectivity of ≥99.5%) + aspheric wide-angle condenser. After 200,000 optical simulations, it achieves "large spot without divergence and no edge distortion", with a maximum area of up to 3.2m×5.0m and uniformity ≤±3%.
Multi-functional compatible design: Supports multiple communication protocols such as Modbus and EtherCAT, and can be seamlessly integrated with AI vision, industrial robots, and environmental chambers. It is suitable for diverse scenarios including certification, production, and scientific research, and can be customized in tabletop sizes ranging from 1m×1m to 3.5m×6.0m.
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