"Sectional testing of super-large-sized photovoltaic modules led to certification failure due to splicing errors, resulting in a loss of millions." "Calibration of aerospace solar sensors, poor uniformity of the light field affects Angle measurement accuracy." "Weather resistance testing of automotive exterior materials, light intensity drift exceeds 8% after long-term operation." "Data distortion makes mass production impossible" - In high-end fields such as photovoltaic module certification, aerospace calibration, automotive industry inspection, and new material research and development, the pain points of traditional solar simulators, such as "small irradiation area, poor steady-state performance, low spectral accuracy, and weak adaptability", are becoming the core bottlenecks restricting product quality upgrading and the transformation of scientific research achievements.
Having been deeply engaged in the field of optoelectronics for over two decades, Saifan Optoelectronics, relying on its accumulation of aerospace-grade optical technology and the iteration of tens of millions of measured data, has launched the 7IS series of large-aperture 3A-level xenon lamp steady-state solar simulators with great fancies. This series takes "maximum 5m×3m ultra-large format irradiation +IEC 60904-9 3A full index long-term compliance +±0.5%/h extreme stable state" as its core competitiveness, integrating high-stability xenon lamp light source and intelligent temperature control technology, perfectly covering the full range of scene demands from the inspection of super-large industrial products to precise scientific research calibration. Today, the 7IS series has become the trusted choice of over 280 high-end enterprises and research institutions worldwide, achieving precise empowerment in fields such as photovoltaic module certification and aerospace calibration, with a customer repurchase rate as high as 52%.
1. Photovoltaic Module Certification: 5-meter large light field, passing international certification in one go
Liu, the head of the certification center of a leading photovoltaic enterprise, once repeatedly encountered obstacles in the certification of super-large-sized modules: "The 5m×2.1m high-efficiency photovoltaic modules we developed have a maximum irradiation surface of only 2m×1.5m in traditional simulators, which can only be tested in sections." However, the error of the segmented splicing exceeded 3%, and the test data was not accepted by international institutions such as TUV and UL. Three certification failures occurred, resulting in a direct loss of over 2 million yuan and also delaying the overseas market launch opportunity. What's even more troublesome is that after the traditional equipment has been running continuously for 2,000 hours, the light intensity drifts by more than 7%, the spectral matching degree drops to grade B, and all the test data accumulated in the early stage becomes invalid.
The "wide range + high stability" feature of the Saifan 7IS series has completely solved the certification problem. This series is equipped with customized ultra-high-power xenon lamp arrays and high-precision optical integrators, supporting customization of irradiation surfaces ranging from 1.2m×1.2m to 5m×3m in multiple specifications. It can fully cover 5m ultra-large-sized photovoltaic modules at one time without the need for segmented testing, with zero splicing error and 100% test data approved by international institutions. The core optical system has been optimized through 300,000 simulations, with an irradiation uniformity of ≤±2% (across the entire irradiation surface), and no distortion at the edges, fully meeting the requirement of uniform irradiation throughout the entire area for super-large-sized components.
With the 7IS simulator, our 5m×2.1m component certification was passed in one go, directly saving 1.8 million yuan in certification costs. We seized the overseas market three months in advance and achieved an annual additional revenue of over 500 million yuan! Engineer Liu happily shared, "The steady-state performance of the equipment has exceeded expectations. It adopts a constant current and constant voltage dual closed-loop drive system, combined with military-grade dual circulation water-cooling temperature control technology. The temperature control accuracy is ±0.05℃. After continuous operation for 10,000 hours, the light intensity drift is ≤±1.5%, and the spectral matching degree always remains ≥97% (AM1.5G standard)." It fully complies with all the requirements of IEC 60904-9 3A. Moreover, the xenon lamp spectrum is infinitely close to natural sunlight, covering the entire wavelength range from 300 to 2500nm. It can accurately reproduce the lighting environment under different atmospheric masses, providing precise data support for the long-term reliability testing of components. In response to the demands of the photovoltaic industry, the 7IS series can also be integrated with the IV testing system to achieve full-process automation of "lighting - electrical testing - data analysis", increasing the testing efficiency by four times.
Ii. Aerospace Calibration: Precise light field, Ensuring the performance of on-board equipment
Engineer Zhao from a certain aerospace research institute once encountered difficulties in the calibration of solar sensors: "Solar sensors are the core components of satellite attitude control, and they have extremely high requirements for the quasi-right Angle, uniformity and stability of simulating sunlight." The quasi-right-angle error of the traditional simulator exceeds 1°, and the uniformity of the irradiation surface is poor, resulting in an Angle measurement accuracy deviation of the sensor exceeding 0.5°, which fails to meet the spaceborne requirements. Moreover, the equipment has poor stability. During the calibration process, the light intensity fluctuates by more than 2% per hour, and the data from multiple calibrations are discrete, which seriously affects the project progress.
The practical application of the 7IS series of aerospace-customized models provides a reliable guarantee for precise calibration. This model adopts a high-precision collimation optical system, and the collimation Angle can be precisely controlled within 32 '±1', perfectly matching the calibration requirements of solar sensors. The irradiation uniformity is ≤±1.5% (in the core irradiation area), the light intensity stability is ≤±0.5%/h, and the repeatability of calibration data for 72 consecutive hours is ≥99.5%, completely solving the problems of accuracy and stability of traditional equipment. The equipment also supports a wide range of continuous adjustable light intensity from 0.1S0 to 1.2S0 (S0 is the solar constant), which can simulate the solar irradiation environment at different orbital altitudes and is suitable for the calibration and testing of various spaceborne solar sensors and starlight shields.
"The 7IS simulator is our 'ground sun'!" " Engineer Zhao gave a thumbs-up, "Its calibration accuracy fully meets the aerospace-grade standards, providing key technical support for our satellite project. It has been successfully applied to the calibration of solar sensors on three satellites in orbit." The equipment is easy to operate and equipped with a user-friendly measurement and control system. It can preset calibration processes, automatically record and export data, significantly reducing the operational difficulty. Moreover, Saifan's technical team provides customized services throughout the process. They optimize the optical system based on our calibration requirements and also offer on-site installation, commissioning and technical training to ensure the equipment is put into use quickly."
Iii. Material Weather Resistance Testing: Long-term steady-state, accurately predicting service life
Mr. Chen, the R&D director of a high-end auto parts enterprise, once paid a heavy price due to distorted material test data: "The automotive exterior coating we developed needs to pass a 10,000-hour weather resistance test to verify its service life." However, after the traditional simulator ran continuously for 3,000 hours, the light intensity drifted by more than 8%, and the energy in the ultraviolet band attenuated by 25%, resulting in a deviation of over three years between the test data and the actual outdoor usage conditions. After the mass-produced models were launched on the market, problems such as coating aging and fading occurred, and the recall losses exceeded 80 million yuan.
The long-term steady-state advantage of the 7IS series provides a precise solution for weather resistance testing of materials. The equipment is equipped with high-quality and long-life xenon lamps, and in combination with the self-developed spectral compensation algorithm, it can compensate in real time for the spectral offset caused by the aging of xenon lamps. After continuous operation for 10,000 hours, the spectral matching degree remains ≥96%, and the energy proportion of each band of ultraviolet, visible and near-infrared is stable, which can accurately reproduce the long-term effect of outdoor natural light. Equipped with environmental simulation modules for high and low temperatures, humidity, and rain, it can comprehensively reproduce the complex outdoor climate conditions. The consistency between the test data and the actual outdoor service life exceeds 95%, and it can accurately predict the actual service life of materials.
Since the introduction of the 7IS simulator, the accuracy rate of our material test data has increased to over 98%, and there have been no quality issues caused by test distortion again. Engineer Chen stated, "The equipment supports 24-hour continuous operation without failure, eliminating the need for frequent shutdowns for maintenance, and the testing efficiency has been increased by three times." Moreover, the size of the irradiation surface can be customized, allowing for the simultaneous testing of multiple component samples and significantly enhancing R&D efficiency. Saifan's after-sales service is also very considerate. The core xenon lamp is guaranteed a 2000-hour service life, and two free on-site calibration services are provided each year to ensure the accuracy and legality of the test data."
Iv. Core Technology Unveiling: Four Breakthroughs, Redefining the Standard for High-End Solar Simulation
The outstanding performance of the 7IS series large-aperture 3A-level xenon lamp steady-state solar simulator stems from the technological accumulation of Saifan Optoelectronics in four major fields: optical design, drive control, heat dissipation system and intelligent algorithm.
- Ultra-large optical design: By adopting a modular array xenon lamp layout and an ultra-large optical integrator, combined with aspheric condensers and high-reflectivity PTFE integrating spheres, it achieves an ultra-large irradiation area ranging from 1.2m×1.2m to 5m×3m. The uniformity of the entire irradiation surface is ≤±2%, and there is no distortion at the edges.
- High-steady-state drive technology: Equipped with a constant current and constant voltage dual closed-loop drive system, the current stability is ≤±0.005%. Combined with an AI adaptive light intensity compensation algorithm, the light intensity stability is ≤±0.5%/h, and the light intensity drift within 10,000 hours is ≤±1.5%, far exceeding the 3A standard requirements.
- Precise spectral replication technology: Utilizing high-quality short-arc xenon lamps, combined with multiple standard filters such as AM1.5G, AM0, and D65, it covers the entire wavelength range from 300 to 2500nm, with a spectral matching degree of ≥97%, capable of accurately reproducing the solar spectrum in various scenarios.
- Military-grade cooling system: Dual-circulation water cooling + intelligent air cooling combined cooling design, temperature control accuracy ±0.05℃, effectively suppressing the influence of temperature fluctuations in the lamp room on the spectrum and light intensity, ensuring the continuous and stable operation of the equipment for 24 hours.
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