Electric Vehicle Full Spectrum Solar Simulation Radiation Testing
System
Complied Standards & Clauses
ISO 12097-2: "Road vehicles-Airbag components-Part 2: Testing Of
airbag modules"
DIN 75220: “Ageing Automobile Components in Solar Simulation Units”
MIL-STD 810 “Environmental Engineering Considerations and
Laboratory Tests”
IEC 60904-9 “Withdrawn Photovoltaic devices - Part 9: Solar
simulator performance requirements”
IEC60068-2-5 “Environmental testing-Part 2-5: Test Sa: Simulated
solar radiation at ground lvel and guidance for solar radiation
testing”
Equipment Overview
This test system is composed of intelligent control power supply,
optimized design of reflector lamp housing, Osram 2000W/4000W metal
halide lamp, cabinet, illuminance meter, etc., which can perfectly
simulate the environment of sunlight under various conditions.
By coupling with environmental factors such as temperature,
humidity, rainfall, and snowfall, it can be used to evaluate the
impact of direct solar radiation on the test sample (thermal,
mechanical, chemical, electrical, etc.), and it can also be used to
reveal the interaction between different materials in the
component. The simulated solar radiation system can be used alone
to test electronics, materials, and small-volume specimens.
Multiple systems can also be combined into a light array through
professional design and layout, which can be used in the tests of
cars, trucks, photovoltaic modules, trains and airplanes.
Technical Parameters
| Radiation range | Up to 500～1200W/m² (Stepless adjustment) |
| Uniformity of light intensity on radiating surface | ±10% |
| The lighting system deviation within continuous 8 hours | ≤±5% |
| After the system lights up stably, it will reach a stabilization
time of ±10% of the set value | ≤2S |
System Structure
The system is composed of a total of 21(3×7) sunlight simulation
units, and each sunlight simulation unit has the same power, which
is 4KW evenly. The specific distribution is as follows:
The size of chamber area in the figure is 6.5m × 2.5m (length ×
width), and each small box is a single sunlight simulation unit.
The distance in the length direction is 1m, the distance in the
width direction is 1.25m, and the height of the irradiation
reference surface is 1500mm±500mm.
The longitudinal centerline of the sunlight simulation device
should coincide with the centerline of the chassis dynamometer in
the vertical direction, and the overall installation position is
above the pit area of the chassis dynamometer.
System Structure
The sunlight simulation unit is composed of a lamp housing, metal
halide lamp and intelligent power supply. The intelligent power
supply is placed outside the test chamber, and the metal halide
lamps are installed in the lamp housing and arranged in the test
chamber according to the required irradiation area.
Lamp source
The main body of the lamp source is sandblasted alumina board
material, which reduces the weight of each sunlight simulation unit
while ensuring the intensity of the lamp source. The reflective
material is imported mirror bean grain aluminum plate, with
reflectivity up to 97%, uniform reflection and no light spots. Due
to the rolling and electroplating process, the high-strength
hardness of the reflective mirror surface is ensured, and the
occurrence of the situation that the reflectivity is greatly
reduced due to the later cleaning and wiping is reduced.
The ignition coil is placed in the power supply. All structures and
components in the lamp source installed in the test space can
withstand a wide temperature and humidity range, and the
temperature resistance is -70℃~+120℃, which also avoids the high
voltage package in the lamp that the long-term resistance to high
temperature in the shell is prone to aging.
Metal halide lamp
Adopt the most advanced metal halide lamp technology. The model is
OSRAM HMI 4000 W/DXS and the specific parameters of the metal
halide lamp are as follows:
| Electrical parameters | Nominal power | 4000W |
|
| Bulb power | 4000W |
| Standard voltage | 200V |
| Bulb voltage | 200V |
| Bulb current | 24 |
| Photometric data | Nominal luminous flux | 380000LM |
| Color temperature | 6000K |
| Color rendering index Ra | 90 |
The spectrum curve of the metal halide lamp itself is very close to
the solar spectrum, and the sunlight can be perfectly simulated
after adjustment by a custom filter. The detailed spectrum curve is
shown on the right.
|  |
Intelligent Power (EPS)
1) The power module adopts high-performance MCU as the control
core, and the high-precision vector control algorithm which
guarantees the stable output of energy, so that the brightness of
the lamp is fixed, and it is not affected by the input grid voltage
and cooling.
2) It can realize 20% to 100% output stepless adjustment, the
overall heat dissipation is small, and it has a variety of control
and communication methods.
| Operation panel display | Operating status | Monitor output voltage, output current, set power, module
temperature, etc. can be selected |
| Parameter setting | Relevant values can be flexibly set according to actual
requirements |
| Protection/alarm function | Overcurrent, overvoltage, undervoltage, overheating, short circuit,
internal memory failure, and etc. |
| Environment | Ambient temperature | -10℃～+50℃ (no freezing) |
| Ambient humidity | Below 90%RH (no frost) |
| Surroundings | Indoor (no direct sunlight, no corrosion, no flammable gas, no oil
mist, no dust, and etc.) |
| Altitude | Less than 1000M |
