HF Litz Wires for Renewable Energy Technology
Driving the Energy Transition through Efficiency
Photovoltaic systems and wind generators convert energy today on a large scale. The profitability of these systems depends directly on the efficiency of their power electronics. High-frequency litz wires from PACK LitzWire minimize power losses in inverters and enable compact, durable designs for maximum efficiency in the energy transition.
In combination with wide-bandgap semiconductors such as silicon carbide (SiC), our optimized HF litz wires enable more compact cooling systems and demonstrably reduce operating costs by up to 40%. We offer reproducible quality and stable electrical properties for maximum efficiency with reduced operating costs.
We supply high-quality HF litz wires to manufacturers for:
- Inverters
- Wind energy systems
- Power plant suppliers
- Combined heat and power (CHP)
Series Production and Reproducibility for the Energy Market
Manufacturers in the energy market require components that can be scaled economically and function reliably for decades.
- Deep Vertical Integration
For over 90 years, we have been manufacturing at our German production facility – from stranding to assembly. This guarantees independence from external suppliers. - Guaranteed Reproducibility
Our fully documented processes ensure consistent quality throughout the entire product lifecycle. - Process Cost Optimization
Our HF litz wires are specifically designed for automated winding processes, which sustainably increases efficiency in your series production. - Rapid Sampling
Through our internal control of all parameters, we ensure fast response times and flexible adjustments for your projects.
Research-Based Optimization for SiC Technology
Wide-bandgap semiconductors such as silicon carbide (SiC) enable higher switching frequencies and more compact inverters. At the same time, winding losses through skin and proximity effects increase significantly at these frequencies. With the help of our research projects, we optimize the electrical properties of our HF litz wires for these new requirements.
Inverters for photovoltaics and wind power work with high switching frequencies and large quantities. Their economic efficiency depends on efficient windings that allow for reproducible manufacturing. The following projects show how PACK LitzWire optimizes HF litz wires for automated series production while improving efficiency and process reliability.
For a manufacturer of solar and wind power systems, PACK LitzWire developed profiled HF litz wires that facilitate automated winding processes and increase the efficiency of inverters and generators. The profiled RUPALIT® HF litz wires with a flattened or square cross-section increased the copper fill factor, enhanced winding layer stability, and facilitated handling in automated winding machines. The fine single wires reduced skin and proximity losses, keeping the windings thermally stable and efficient. The result: consistent quality in series production, significantly improved efficiency, and increased cost-effectiveness of production.
In modern inverters for photovoltaic and wind power systems, toroidal transformers are central components for high efficiency and grid quality. PACK LitzWire developed a customized HF litz wire for a manufacturer of PV and wind power inverters that combines mechanical stability, high fill factor, and fast series production. By specifically varying the lay length and lay direction as well as optimizing the single wire diameter, a litz wire was developed that prevents unraveling during winding and protects the insulation from damage. The result: increased process speed on the toroidal winding machines and a constantly high copper fill factor.
For a manufacturer of solar and wind power systems, PACK LitzWire developed profiled HF litz wires that facilitate automated winding processes and increase the efficiency of inverters and generators. The profiled RUPALIT® HF litz wires with a flattened or square cross-section increased the copper fill factor, enhanced winding layer stability, and facilitated handling in automated winding machines. The fine single wires reduced skin and proximity losses, keeping the windings thermally stable and efficient. The result: consistent quality in series production, significantly improved efficiency, and increased cost-effectiveness of production.
In modern inverters for photovoltaic and wind power systems, toroidal transformers are central components for high efficiency and grid quality. PACK LitzWire developed a customized HF litz wire for a manufacturer of PV and wind power inverters that combines mechanical stability, high fill factor, and fast series production. By specifically varying the lay length and lay direction as well as optimizing the single wire diameter, a litz wire was developed that prevents unraveling during winding and protects the insulation from damage. The result: increased process speed on the toroidal winding machines and a constantly high copper fill factor.
Maximize Efficiency, Lower Costs
- Frequency-dependent litz wire optimization for SiC and GaN inverters.
- Design-for-manufacturing consultation for automated series production.
- Simulation support for calculating your individual AC power loss.
