Design, fabrication and experimental analysis of A 5 kVA hybrid Solar inverter with MPPT Charge Controller for improved energy efficiency

Abstract

The increasing global demand for reliable, efficient, and sustainable energy 
systems has intensified the need for advanced solar power conversion 
technologies capable of maximizing photovoltaic (PV) energy utilization. This 
study presents the design, development, and performance evaluation of a 5 kVA 
hybrid solar inverter integrated with a Maximum Power Point Tracking (MPPT) 
charge controller to enhance overall system efficiency and operational 
reliability. Conventional inverter systems employing Pulse Width Modulation 
(PWM)-based charge controllers often exhibit reduced energy conversion 
efficiency, particularly under fluctuating solar irradiance and varying load 
conditions. To address these limitations, an advanced MPPT-based DC–DC 
converter was incorporated into the system to dynamically track and maintain 
the PV array at its optimum operating point for maximum energy extraction. 
The developed hybrid system consists of a 5 kVA pure sine wave inverter rated 
at 230 V AC and 50 Hz, a 48 V battery bank, a high-efficiency MPPT charge 
controller, and an intelligent hybrid switching mechanism enabling seamless 
integration of solar, battery, and grid/generator power sources. Both simulation 
and experimental analyses were conducted under varying irradiance and load 
profiles to evaluate system performance. Results revealed that the integrated 
MPPT controller enhanced solar energy harvesting efficiency by approximately 
15–25% compared to conventional PWM-based systems. The inverter maintained 
stable voltage regulation within ±2%, frequency stability of ±0.5 Hz, and total 
harmonic distortion below 3%. Furthermore, the implemented multi-stage 
battery charging strategy improved storage efficiency, minimized battery 
stress, and prolonged battery lifespan. The study demonstrates that 
integrating advanced MPPT control significantly improves energy utilization 
efficiency, system reliability, and the techno-economic viability of hybrid solar 
power systems for residential and small-scale commercial applications.