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Today's standard practice requires workers to lift heavy panels (~35 kg) at arm's length while on ladders—exposing them to falls, musculoskeletal injuries, slow positioning, and inconsistent quality. Improving safety while accelerating installation represents a critical industry challenge.
In collaboration with EDF Power Solution, this R&D project produced a frugal, ergonomic, and robust toolset for photovoltaic panel installation—simultaneously reducing workplace hazards, boosting efficiency, and ensuring consistent quality across installations.
A secure gripping system for photovoltaic panels, adaptable to varying thicknesses. Its toggle-clamp mechanism enables rapid locking and release, while protective rubber pads prevent surface damage during handling.
A deceptively simple yet highly effective accessory that prevents panels from sliding once positioned at height, ensuring precise alignment without repeated measurements or adjustments.
Purpose-built adapters (including models for Araymond clamps) enable operators to secure panel frames directly to supporting purlins from ground level. Compatible variants for other clamp systems such as Axial ensure universal applicability across installation contexts.
Magnetic spacers maintain consistent module spacing during installation—a hands-free solution that ensures optimal alignment and quality while eliminating post-installation corrections.
This user-centered, field-validated approach resulted in patent FR3149369A1 protecting the innovative handling and installation system. Between 2022 and 2025, the project followed a rigorous design methodology: from field immersion and timed observation, through iterative prototyping, to collaborative validation with EDF installation teams.
A – 2022 – Field immersion, filmed timing
B – 2022 – Team Workshops
C – 2022 – R&D Design Project, HSE focus
D – 2023 – Concept Generation
E – 2023 – Technical Demonstrator
F – 2023 – Tests & Feedback (REX)
G – 2023 – User Scenarios & Simulation
H – 2023 – V2 Design + Accessories
I – 2023 – Prototype V2 Fabrication
J – 2025 – Patent
K – 2025 – KIT Fabrication
Recent field tests demonstrate safe, ladder-free installation—a transformative HSE improvement—while reducing installation time and enhancing quality consistency. The next phase focuses on establishing industrial partnerships for large-scale manufacturing and deployment across the renewable energy sector.