"For the 10,000-hour certification of photovoltaic modules, three traditional devices were rotated for testing but still had to be reworked due to drift, resulting in an additional investment of 4 million yuan." "In the weather resistance test of automotive coatings, inaccurate spectra led to color differences in mass-produced models and recalls, causing losses of over 80 million yuan." "In photocatalytic research, high equipment energy consumption + data dispersion "Despite a 30% overrun of project funds, no breakthrough achievements have been made" - In scenarios such as long-term reliability testing, industrial product verification, and cutting-edge research, the triple pain points of "poor stability, insufficient precision, and uncontrolled energy consumption" are becoming the "roadblocks" for enterprises to improve quality and efficiency and transform scientific research achievements.
Saifan Optoelectronics has been deeply engaged in optoelectronic technology for 20 years, integrating the world's top optical resources and tens of millions of measured data to create a 3A-level steady-state solar simulator. With the three core advantages of "IEC 60904-9 3A full index long-term compliance + intelligent switching of xenon lamp/LED dual light sources + green energy-saving system", It covers the demands of all fields including photovoltaic, automobiles, building materials, scientific research, etc. Today, this "All-in-One Light Testing Machine" has served over 320 high-end customers worldwide, achieving zero rework in long-term testing, zero deviation in product verification, and zero waste in scientific research experiments. The overall usage cost has been reduced by 50%, making it a trusted "testing efficiency engine" in various industries.
1. Photovoltaic Module 10,000-hour Certification: 1 unit is equivalent to 3 units, with long-term stable state zero rework
Li, the certification director of a leading domestic photovoltaic enterprise, was once pushed to the "dead end" by the 10,000-hour reliability certification: "To strive for the highest level of TUV Rheinland certification, we put three traditional simulators into rotation testing. After running for 5,000 hours, the light intensity drift generally exceeded 7%, and the spectral matching degree dropped to grade B. The certification body directly rejected the data." Eight months were wasted from start to finish, with additional testing costs and component losses exceeding 4 million. The product's overseas expansion plan was seriously delayed. What is even more troublesome is that the splicing error in the segmented testing of 210mm super-large size components greatly reduces the credibility of the certification data.
The "long-duration steady-state black technology" of the Saifan 3A-level steady-state solar simulator has completely ended the nightmare of "repeated testing". The equipment is equipped with the 8th generation intelligent steady-state drive system, which adopts constant current and constant voltage dual closed-loop control + AI adaptive compensation algorithm. The current stability reaches ±0.005%. Combined with the military-grade dual circulation water cooling system (temperature control accuracy ±0.05℃), the light intensity drift is ≤±1.2% after continuous operation for 10,000 hours. The spectral matching degree has always remained at ≥97.5%, far exceeding the IEC 60904-9 3A standard. Equipped with a 3.2m×5.0m ultra-large format uniform light system, it can cover 210mm + full-size components at one time, with zero splicing error. The test data has been 100% reviewed by international institutions such as TUV, UL, and IEC.
"Now, one Saifan device can complete the workload of the previous three. The 10,000-hour certification can be passed in one go, directly saving 4 million yuan in rework costs." " Engineer Li did a precise calculation: The equipment supports intelligent switching between xenon lamps and LED dual light sources. The xenon lamp for high-end certification (with a spectral fidelity of 98%) and the LED for mass production inspection (with a lifespan of 100,000 hours) have reduced the annual lamp replacement cost from 200,000 yuan to 30,000 yuan. The intelligent calibration system automatically calibrates every 100 hours without the need for manual supervision, saving the salaries of 5 calibration engineers by 300,000 yuan annually. The energy consumption is reduced by 60% compared with traditional equipment, saving 450,000 yuan in electricity bills annually. Previously, the quoted price for imported equipment was 13 million yuan, with a delivery period of 10 months. The customized version of Saifan is only 6.5 million yuan, with delivery within 45 days. It also offers full technical support throughout the certification process, helping us enter the European market six months ahead of schedule and increase annual revenue by over 800 million yuan.
Ii. Weather Resistance Testing in the Automotive Industry: Precisely replicating sunlight, zero deviation in product verification
Zhang Gong, the materials research and development manager of a certain joint venture car brand, once paid a heavy price due to a "spectral error" : The new generation of automotive exterior coating we developed has a weather resistance life of 12 years as tested on traditional simulators. One year after the mass-produced models were launched on the market, severe color differences and cracking problems occurred in many places. Eventually, 100,000 vehicles were forced to be recalled, resulting in losses of over 80 million yuan. Post-event investigation revealed that the ultraviolet band energy deviation of traditional equipment exceeded 35%, making it impossible to replicate the real outdoor lighting environment at all."
Saifan's industry-customized solutions enable the automotive industry to achieve "zero deviation" in testing. The device is equipped with a dedicated spectral library for the automotive industry. It precisely optimizes the energy proportion of the 280-400nm ultraviolet band for different materials such as coatings, plastic parts, and rubber. The spectral matching degree is ≥98.5%, and the consistency with the actual outdoor lighting conditions exceeds 97%. Combined with distributed uniform light technology, the irradiation uniformity is ≤±2%, the temperature difference of the entire board material is ≤±0.8℃, and the deviation of the test data of the same batch is ≤0.8%, which can accurately predict the actual service life of the product.
The weather resistance test data of the newly developed coatings now deviates from the outdoor exposure results by no more than 0.5 years, and there have been no recall issues since then. Engineer Zhang introduced that the equipment supports continuous 7,200 hours of extreme weather resistance testing. Combined with the high and low temperature, humidity and rain linkage system, it can simulate different climate environments such as deserts, beaches and plateaus, and the testing efficiency is increased by three times. The energy consumption advantage is more prominent: "Previously, the annual electricity cost for four traditional devices was 600,000 yuan, and the maintenance cost was 250,000 yuan." Now, the annual electricity cost for one Saifan Steady-state device is only 120,000 yuan, and the maintenance cost is 30,000 yuan. In just three years, the equipment investment can be saved, and 70% of the laboratory space can also be reduced.
Iii. Cutting-edge Scientific Research Experiments: Precise Regulation + Energy Conservation and Consumption Reduction, with 50% acceleration in Technology Transfer
Professor Wang from the School of Chemistry at a 985 university was once worried about his research project on photocatalytic water splitting: "We need to precisely control the light intensity and spectral composition. However, traditional simulator light emphasizes a coarse step size (5%), and the spectrum is fixed and unadjustable. The degradation efficiency of the same batch of experiments deviates by more than 20%, and we haven't published a single top-tier journal paper in three years." What's even more fatal is that the equipment has a high power consumption and high energy consumption. The annual electricity bill exceeds 200,000 yuan, the project funds are over 30% in excess, and the transformation of research results is still a long way off.
The research customization model of Saifan's 3A-level steady-state solar simulator has brought about a "qualitative leap" in research efficiency. The device supports continuous adjustment of light intensity with an accuracy of 0.1%, and independent control of ultraviolet, visible and near-infrared bands (with an accuracy of 1%). It can simulate the lighting conditions in different natural environments and is suitable for various scientific research scenarios such as photocatalysis, photoelectric conversion and plant cultivation. Equipped with an intelligent energy-saving system, it automatically adjusts the power output according to the experimental requirements, saving 55% energy compared with traditional equipment, and the annual electricity cost is only 80,000 yuan.
"Now the repeatability of experimental data has increased from 60% to 99%. Last year alone, four SCI top journals were published, among which two were selected as ESI highly cited papers." " Professor Wang excitedly said that a single unit of the equipment can cover a 200-square-meter pilot platform, with a light uniformity of 97%. Combined with the upper computer software, the light change curve can be preset, and it can be seamlessly linked with the reaction vessel and mass spectrometer to achieve full-process automation of "light - detection - data analysis". "Previously, it required six people to operate in shifts, but now one person can complete it." The project funds were saved by 30%, the cycle for technology transfer was shortened from 5 years to 2 years, and the annual new output value exceeded 100 million yuan after implementation.
Iv. Core Technology Unveiling: Three Major Breakthroughs, Redefining the Standards of Light Testing
The core competitiveness of Saifan's 3A-level steady-state solar simulator stems from three breakthrough technologies in the industry:
Long-term steady-state technology: 8th generation constant current and constant voltage dual closed-loop drive + AI adaptive compensation algorithm, current stability ±0.005%, dual-circulation water cooling system temperature control accuracy ±0.05℃, light intensity drift within 10,000 hours ≤±1.2%, far exceeding the 3A standard requirements.
Dual-light source intelligent architecture: Seamless switching between xenon lamp and LED dual light sources. The spectral matching degree of the xenon lamp version is ≥98% (compatible with high-end certification), and the lifespan of the LED version is 100,000 hours (compatible with mass production testing). It supports automatic selection of the optimal light source based on testing requirements.
Green energy-saving system: Utilizing high-efficiency optical lenses and intelligent power regulation technology, energy consumption is reduced by 60% compared to traditional equipment. Coupled with a waste heat recovery module, the heat generated during equipment operation can be recovered for laboratory heating or hot water supply, achieving an annual energy-saving benefit of over 500,000 yuan.
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