Design and development of car’s windshield lifting tool for end-of-life vehicle dismantling process

Ahmad Husaini, Muhammad Ameer (2025) Design and development of car’s windshield lifting tool for end-of-life vehicle dismantling process. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Customised windshield lifting tool for dismantling end of life vehicles (ELVs) solves some significant issues such as safety issues and environmental concerns as well as efficiency issues of the dismantling process. Traditional techniques of the removal of windshields involve the use of unskilled manual labour, which is dangerous, time-consuming, likely exposes the windshields to physical damage therefore calling for an innovation. In this research, major design parameters such as adjustability, ergonomics, safety, ease of use, durability, and compatibility are incorporated into the design of the required tool. CAD software and FE analysis are employed to validate the tool’s mechanical performance and functionality in different operating states. As a functional prototype of the tool, the 3D printing approach made it possible to physically interact with the designed tool and assess its functionality. The testing proved enhanced effectiveness in operation, safety of workers, and efficiency of windshield removal in comparison to the initial practices. It is also important to note that the tool is made from lightweight but durable materials like aluminium alloys and stainless steel so that it does not add to the manual stress on workers but at the same time is very durable and long lasting. The practicality and applicability to numerous automotive models appeals to the effectiveness and efficiency that is inherent in the automotive recycling business. Apart from operation significance, the windshield lifting tool helps to achieve some goals as to sustainability since the use of valuable materials allows recycling them without negative impacts on the environment. They are in harmony with the concept of the circular economy, encouraging the subsequent use of the auto part and limiting the utilization of raw material for developing automotive. This study provides a new paradigm shift in ELV dismantling as it focuses on implementation of a new approach that could ensure increased safety, effectiveness, and most importantly, environmental care. The results outlined in this study can be considered to show the remarkable roles of advanced technologies in engineering in bringing about significant changes in mainstream industries in automotive recycling. This tool was considered as a significant contribution to solving the urgent problems in ELV management and contributing to improving sustainability in the automotive industry.

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