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Create a miracle in 90 days! Uncover the "extreme operations" behind the Photovoltaic Laboratory Project of Changzhou Architectural Research Institute Group Co., Ltd
The project covers core functions such as component performance testing, environmental simulation, and electrical safety. It is planned to pass the professional review before the end of 2024 and undertake the testing and certification business of the photovoltaic industry chain in the Yangtze River Delta region.
The project involves more than 20 categories of specialized equipment, including high-precision instruments such as Steady Sun Simulator, UV preconditioning chambers and mechanical load testers, which need to meet the requirements of international standards such as IEC 61215/61730.
1) Master Control Table for Equipment Arrival: Based on the experience of more than 20 previous laboratory projects, a priority matrix for equipment arrival was formulated. Seven suppliers were coordinated to deliver goods accurately in five batches, increasing the site utilization rate by 60%.
2) Three-dimensional Modeling and Pre-rehearsal: Use BIM technology to build a 1:1 model of the laboratory, and discover in advance the conflict points between the environmental chamber and the building structure, reducing on-site rework three times.
3)Problem Closed-loop Mechanism: Establish a four-step working method of "discovery-evaluation-solution-verification", and a total of 52 technical problems have been handled. A typical case is the 24-hour emergency response to the deviation between the physical environmental chamber and the drawings.
In response to the stringent temperature control requirements of the laboratory, the independently developed Panfile temperature simulator innovatively integrates a PID intelligent temperature control system and superimposes a powerful air duct circulation system, overcoming the problem of test stability of photovoltaic modules in a large temperature difference environment (from 15°C to 80°C). It has achieved two core values for the project of Changzhou Architectural Research Institute Group.
1) Precise Temperature Control to Ensure Data Authority: The temperature resolution is accurate to 0.1°C, and the temperature deviation on the surface of the module is ±1°C. The temperature control stability is strong (within 5 seconds of opening the door, the temperature fluctuation on the surface of the module is less than 0.5°C). It provides reliable data support for IEC standard certification;
2) Long-term Operation to Enable Efficient Detection: It can maintain a stable working state during long-term measurement and control, without significant fluctuations in temperature readings or control. It helps the laboratory improve the daily average detection efficiency and becomes a key technical guarantee for the project's acceptance on schedule.
3. Hierarchical Empowerment Training System
| Training Hierarchy | Course Module | Deliverables |
|---|---|---|
| Operational Level | Equipment Operation / Daily Maintenance / Emergency Handling | Practical operation assessment with a pass rate of 100% |
| Technical Level | Interpretation of Testing Standards / Data Analysis | Ability to independently compile testing reports |
| Management Level | Laboratory Operation / Quality Control | Customized SOP (Standard Operating Procedure) manual for quality control |
Part 3. Reliable Delivery: Cross-departmental Collaborative Operations
In order to ensure the perfect implementation of the above plans, I coordinated the following guarantee mechanisms with the company and the client:
1. Establish a Technical Breakthrough Commando Team:
Eight senior engineers from various departments were seconded to form a special task force. They tackled the problem of matching the power load of the environmental chamber, optimized the power distribution plan, and saved 15% of energy consumption.
2. Establish a Deep Collaboration Mechanism with the Client:
A system of daily on-site progress meetings at 18:00 was established. A total of 27 requirement changes were resolved. An innovative spiral improvement model of "Training - Feedback - Optimization" was adopted, which greatly improved client satisfaction.
As the saying goes, no pains, no gains. It has been proven that hard work never goes unrewarded. In December 2024, the laboratory successfully passed the on-site CNAS assessment at one go.
Service Network: A 7×24-hour online operation and maintenance system, and a mechanism for extremely fast response within 2 hours for key spare parts.
Epilogue:
The project delivery for the Changzhou Architectural Research Institute Group has been successful. However, the long journey of exploration for the people of Zealwe Technology is far from over.
At a time when the photovoltaic industry has entered a new stage of "quality competition", Zealwe Technology will continue to be driven by innovation and create more testing infrastructure for the industry that can stand the test of time.
