"Photovoltaic module 10,000-hour reliability test, light intensity drift exceeded 6%, certification data rejected" "Weather resistance test of automotive interior materials, spectral deviation led to a 50% reduction in actual service life" "Photocatalytic research experiment, poor light uniformity, data repeatability less than 65%" - In the fields of photovoltaic manufacturing, automotive industry, new material research and development, and cutting-edge scientific research, The pain points of "insufficient long-term stability, inaccurate spectral replication, poor uniformity and excessive energy consumption" are becoming the core bottlenecks restricting product quality and scientific research efficiency.
Having been deeply engaged in optoelectronic technology for 20 years, integrating the world's top optical resources and tens of millions of measured data, we have launched a 3A-level steady-state solar simulator. With the three core advantages of "IEC 60904-9 3A full index long-term compliance + precise spectral replication + full-scene customized adaptation", It perfectly covers the strict lighting requirements from industrial mass production certification to high-end scientific research experiments. Today, this "all-round Artificial Sunlight King" has served over 300 high-end customers worldwide, achieving a long-term test accuracy drift of ≤±1%, a spectral matching degree of ≥98%, and a 55% reduction in comprehensive energy consumption. It has become the "trusted choice" for light testing in various industries.
1. Photovoltaic Module Certification: 10,000-hour steady-state zero drift, passing international certification in one go
Mr. Liu, the certification director of a leading photovoltaic enterprise, has repeatedly encountered obstacles in the international certification of components. To strive for the highest level of TUV Rheinland certification, we need to conduct stable tests for 10,000 consecutive hours. After running the traditional simulator for 5,000 hours, the light intensity drift exceeds 6%, and the spectral matching degree drops to grade B. All the 3 million yuan in testing costs and six months invested in the early stage have been wasted. What is even more challenging is that the 210mm large-sized components need to be tested in sections, with a splicing error exceeding 3%, and the certification data cannot be accepted by international institutions."
The "long-term steady-state core technology" of the 3A-level steady-state solar simulator has completely solved the certification problem. The equipment adopts the 8th generation constant current and constant voltage dual closed-loop drive system, combined with military-grade dual circulation water-cooled temperature control (accuracy ±0.05℃). After continuous operation for 10,000 hours, the light intensity drift is ≤±1%, and the spectral matching degree always remains ≥98%, 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. All test data have passed the review of international institutions such as TUV, UL, and IEC 100%.
"Now, the 10,000-hour certification is passed in one go, the component premium has increased by 12%, and the annual new revenue exceeds 500 million yuan." " Engineer Liu's tone was full of approval: "What impressed us the most was its stability. Even after running for 8,000 hours, the light intensity drift was still controlled within 0.8%. The review experts from TUV all praised that 'the data stability is comparable to that of top international equipment.'" " The device supports one-click switching of multiple standard spectra such as AM1.5G/AM0/D65, with continuously adjustable light intensity ranging from 100 to 2000W/m², meeting the certification requirements of different regions around the world. The intelligent calibration system automatically calibrates every 200 hours without manual intervention, saving 240,000 yuan in labor costs for four calibration engineers annually. Previously, importing 3A steady-state equipment cost 11 million yuan, with a delivery period of 8 months. Our customized model is only 5.5 million yuan, delivered within 45 days, and we also offer full technical support throughout the certification process. Domestic equipment has completely broken the international monopoly."
Ii. Material Weather resistance Test: Precise spectral replication, zero deviation in actual life prediction
Mr. Zhang, the materials research and development manager of a certain car manufacturer, once paid a heavy price due to a "spectral error" : "The car exterior materials we developed had a weather resistance life of 10 years when tested on traditional simulators. Three years after the mass-produced models were launched on the market, cracking and discoloration problems occurred in many places. Eventually, we were forced to recall 50,000 vehicles, resulting in losses of over 60 million yuan." Post-event investigation revealed that the ultraviolet band energy deviation of traditional equipment exceeded 30%, making it impossible to replicate the real outdoor lighting environment at all."
The "precise spectroscopy technology" of the 3A-level steady-state solar simulator enables "zero deviation" in material testing. 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 the natural sunlight spectrum is ≥98.5%, especially the energy restoration accuracy in the ultraviolet (300-400nm) and near-infrared (760-1100nm) bands exceeds 97%. Accurately reproduce the complex outdoor lighting conditions. Combined with a distributed uniform light system, 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 ≤1%, which can accurately predict the actual service life of the material.
"Now, the actual service life of the material deviates from the test value by no more than 0.5 years, and there have been no more recall issues." " Zhang Gong said with deep feeling, "We compared the test data of the equipment with the results of the outdoor sun exposure field in Arizona, USA. The consistency was as high as 97%. Colleagues from the technical department joked, 'From now on, there's no need to send samples all the way for sun exposure. This equipment is like a mobile outdoor test field.'" The equipment supports continuous 7,200 hours of extreme weather resistance testing. Combined with a 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 six traditional devices was 500,000 yuan, and the maintenance cost was 250,000 yuan." Now, the annual electricity cost for one steady-state device is only 80,000 yuan, and the maintenance cost is 40,000 yuan. In just three years, the equipment investment can be saved, and 70% of the laboratory space is also reduced.
Iii. Cutting-edge Scientific Research Experiments: Flexible regulation + Low Noise and Energy saving, with a 40% acceleration in technology transfer
Professor Wang from the School of Chemistry at a 985 university was once worried about photocatalytic research experiments: "When we study photocatalytic hydrogen production, 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 hydrogen production efficiency of the same batch of experiments deviates by more than 20%, and we haven't published a single top journal paper in four years." What's even more fatal is that the operating noise of the equipment exceeds 70 decibels, which affects the operation of precision instruments. The annual electricity bill exceeds 200,000 yuan, and the project funds are seriously overspent.
The research customization version of the 3A-level steady-state solar simulator enables 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. Adopting low-noise light source driving technology, the operating noise is ≤55dB, close to the background noise of the laboratory, and does not interfere with precision instruments and biological experiments. Equipped with an intelligent energy-saving system, it saves 55% energy compared to traditional equipment, and the annual electricity bill is only 70,000 yuan.
"Now the repeatability of experimental data has increased from 65% to 99%. Last year alone, four SCI top journals were published, among which one was selected as an ESI highly cited paper." " Professor Wang excitedly said, "The precise control ability of this device exceeded expectations. The 0.1% light emphasis node step size enabled us to accurately capture the reaction critical point. The review experts all praised, 'The experimental data is solid and reliable.'" 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, it can preset the light change curve and seamlessly interact with the reaction vessel and mass spectrometer to achieve full-process automation of "light - detection - data analysis". "Previously, five people were needed to operate in shifts, but now one person can complete it. The project funds were saved by 35%, the cycle of technology transfer was shortened from 5 years to 3 years, and the annual new output value exceeded 80 million yuan after implementation.
Iv. Core Technology Unveiling: Three Major Breakthroughs, Redefining the Standards of Light Testing
The core competitiveness of the 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%, far exceeding the 3A standard requirements.
Precise spectral replication technology: High consistency light source array + 7th generation spectral fitting algorithm, spectral matching degree ≥98.5%, full-band energy restoration accuracy over 97%, meeting international standards such as IEC 60904-9 and ASTM G155;
Intelligent energy-saving system: High-efficiency optical lenses and intelligent power regulation technology reduce energy consumption by 55% compared to traditional equipment. Combined with a waste heat recovery module, the heat generated during equipment operation can be recovered for laboratory heating, achieving an annual energy-saving benefit of over 400,000 yuan.
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