The PVwins project, funded under the German research grant FKZ 03EE1062X, aimed to integrate photovoltaic modules into noise‑barrier walls along roadways, thereby combining renewable energy generation with acoustic protection. Over a three‑year period, the consortium developed and tested a range of module concepts, performed detailed numerical analyses, and constructed a full‑scale demonstrator that was monitored under real‑world conditions.

The technical work began with a comprehensive requirements analysis (AP 1) that defined performance targets for both electrical output and acoustic attenuation. In the module‑development phase (AP 2), several design concepts were categorised and subjected to finite‑element modelling (MS 2.1). These simulations evaluated mechanical stresses, thermal behaviour, and the interaction between the PV cells and the absorber material. Two primary mounting solutions were explored: a prefabricated frame (Vorbaulösung) and a direct‑mounting approach (Aufsatzlösung). Optimisation of the concepts (MS 2.3 & 2.4) led to the selection of a laminated structured‑film technique (MS 2.5) that improves both structural integrity and acoustic absorption. A life‑cycle assessment (MS 2.7) quantified the environmental benefits, showing a reduction in embodied energy compared with conventional barriers.

Manufacturing trials (AP 3) translated the laboratory concepts into production‑grade modules. MS 3.1 described the adaptation of the designs to an industrial production line, while MS 3.2 focused on modules for the in‑situ demonstrator. Five distinct concepts were fabricated, including a combination solution (Konzept 7), a micro‑perforated absorber (Konzept 4), an integrated standard module for the road‑side (Konzept 8), a cassette solution (Konzept 9), and a dual‑orientation mounting (Konzept 6). These modules were assembled into a full‑scale noise‑barrier wall and subjected to rigorous testing.

Electrical integration (AP 6) addressed system connectivity, safety, and cost comparison between module optimisers and module inverters (MS 6.1). Failure‑mode and effects analysis (FMEA) identified critical points, and operational strategies (MS 6.2) were developed to maximise energy yield. Local energy utilisation concepts (MS 6.3) and detailed monitoring of power output (MS 6.5) demonstrated that the integrated PV‑barrier produced measurable electricity while maintaining acoustic performance. Mechanical robustness was verified through stone‑impact tests in accordance with DIN EN 1791‑1 (MS 4.3), confirming that the modules withstand typical road‑side debris impacts.

The demonstrator (AP 7) was installed along a test section of a German highway. MS 7.1 described the construction of the noise‑barrier wall, and MS 7.2 detailed the grid connection and real‑time monitoring system. Continuous data collection over the project duration provided empirical evidence of the dual functionality, showing that the PV‑barrier achieved the targeted acoustic attenuation while delivering a stable power output that could be fed into the local grid.

Collaboration was central to the project’s success. Fraunhofer ISE led the research and development, providing expertise in PV technology, acoustic modelling, and life‑cycle assessment. The construction firm Kohlhauer supplied practical experience in building and installing the barrier wall, and also participated in the design of mounting systems. Additional partners included Fraunhofer IBP, which contributed to the “Climate‑Neutral Noise‑Barrier” study, and the Austrian ASFINAG, which tested a section of the PV‑barrier under the IÖB Challenge. The German Federal Ministry of Transport and Digital Infrastructure (BASt) commissioned a study on legal frameworks and business models, further informing the project’s implementation strategy. The consortium’s work has already led to subsequent EU projects, industry collaborations, and several peer‑reviewed publications, underscoring the broader relevance of integrating photovoltaic modules into noise‑barrier infrastructure.