The PV‑MoVe project, funded by the German Federal Ministry of Economic Affairs and Climate Action (BMWK) under the call “Promotion of research and development projects in the field of power electronics for energy efficiency increase (LES)”, was carried out from 2019 to 2022 and managed by the project carrier PTJ in Jülich. The main partner was SUMIDA Components & Modules GmbH, whose research and development activities are based in Obernzell, Germany. The project’s objective was to develop novel inductive components that enable fast switching in photovoltaic (PV) inverters, thereby improving energy efficiency and reducing weight. The authors of the report hold full responsibility for the content, and the project was supported financially by BMWK and overseen by PTJ.
Technically, the project achieved significant advances in the design, simulation, and dimensioning of inductive power elements for multiphase PV boosters and inverter chokes. A key milestone was the development of an optimized power choke capable of operating at a switching frequency of 100 kHz, a substantial increase from the conventional 20 kHz standard. This new design achieved a 60 % reduction in weight while maintaining performance, as illustrated in the comparative figures of the report. The weight distribution of a 25 kW inverter, based on the latest scientific state, was also optimized, demonstrating the practical applicability of the new components in real‑world systems.
The project also addressed ancillary challenges such as electromagnetic interference (EMI) filtering and demodulation. Dedicated simulation and design work produced efficient EMI filter modules that meet stringent regulatory requirements. Passive switching load components, including a galvanically isolated active snubber transformer, were simulated, designed, and dimensioned to improve voltage handling and reduce losses. Thermal management was tackled through the investigation of heat‑pipe and active cooling concepts, ensuring reliable operation at high switching frequencies. A calorimeter, upgraded with a dedicated drive unit, was developed to accurately measure loss power in the new magnetic elements, enabling precise model building and validation.
Iterative prototyping formed a core part of the effort. Two successive iterations of the inductive elements were fabricated and tested, with each cycle refining the low‑inductance assembly and interconnection techniques. Loss determination and model building were performed for each iteration, feeding back into the design cycle and ensuring convergence toward the target specifications. The project also produced a cooling concept tailored to the originally planned application, further enhancing the reliability of the high‑frequency inverter modules.
From a collaboration perspective, the project involved close coordination between SUMIDA and external research institutions, with joint work packages covering simulation, design, prototyping, and testing. The project’s outcomes are intended to be transferred into mid‑ to long‑term product and system solutions by SUMIDA, with production planned in Germany and worldwide distribution. The exploitation plan outlines economic and scientific benefits, including the integration of the new knowledge into future passive component development for other power classes, potential applications in electric mobility, uninterruptible power supplies, and battery storage systems, and the creation of new jobs through serial production.
In summary, the PV‑MoVe project delivered a suite of high‑performance inductive components that enable PV inverters to operate at 100 kHz with significant weight savings, while also advancing thermal management, EMI filtering, and loss measurement techniques. The collaboration between SUMIDA, PTJ, and other partners under BMWK funding has positioned the company to commercialize these innovations and expand its competitive edge in the power electronics market.