Design and fabrication of a manual ELV brake pad and disc separation device for end-of-life vehicle (ELV)

Berhaman, Budriz (2025) Design and fabrication of a manual ELV brake pad and disc separation device for end-of-life vehicle (ELV). Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

Text (Full Text) Design and fabrication of a manual ELV brake pad and disc separation device for end-of-life vehicle (ELV).pdf - Submitted Version Download (2MB)

Abstract

End-of-life vehicles (ELVs) pose substantial challenges in recycling due to hazardous materials and the complexities involved in disassembly, particularly with brake components. Brake disassembly is a critical yet risky process, requiring specialized tools and expertise to safely handle materials like asbestos and brake dust. This study aims to address these challenges through the design and fabrication of a manual brake pad and disc separation device specifically for ELVs. The device was developed with a focus on safety, efficiency, and environmental sustainability, featuring ergonomic design, durable materials, and cost-effective fabrication. By analysing existing disassembly methods, identifying risks, and optimizing design parameters, the resulting prototype ensures operational stability and adaptability across various vehicle types. Practical testing and simulations demonstrated its effectiveness in reducing manual labour, improving safety, and facilitating the recovery of recyclable materials. This tool enables safer handling of hazardous materials, reduces environmental impact, and promotes resource conservation by increasing the efficiency of material recovery. Its compact and versatile design makes it suitable for small- and medium-scale recycling facilities, addressing cost constraints and operational inefficiencies in the recycling industry. Furthermore, it supports the circular economy by enhancing the recycling of valuable brake materials while minimizing waste. The study concludes that this device offers a practical and scalable solution for advancing sustainable practices in ELV recycling. Recommendations for future development include the use of lightweight materials for increased portability, modular designs to accommodate a broader range of vehicle models, and semi-automation to further enhance efficiency and reduce labour dependency. By integrating such innovations, the device could significantly contribute to safer, more effective, and environmentally friendly automotive recycling processes, addressing critical gaps in current ELV management systems. This research lays the groundwork for future advancements in sustainable vehicle recycling technologies.

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