Design and construction of a portable ELV battery removal tool

Zulkifli, Dini Hakimi (2025) Design and construction of a portable ELV battery removal tool. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The automotive industry has seen significant growth in recent years, leading to a higher number of vehicles on the road. However, as these vehicles reach the end of their life cycle, proper disposal of their components becomes crucial. Among these components, end-of-vehicle-life (ELV) batteries pose a challenge due to their hazardous materials like lead-acid electrolytes and heavy metals. Disassembling ELV batteries is essential to minimize environmental pollution and ensure safe handling of hazardous materials. However, the process faces challenges in terms of safety, efficiency, and compatibility with various battery types. To address these challenges, a project aims to develop a portable tool specifically designed for removing ELV batteries. This tool will be user-friendly, adhere to safety regulations, and work effectively with different battery types. The goal of the project is to create an innovative and efficient tool for ELV battery removal, contributing to sustainable practices in the automotive industry. By optimizing disassembly processes, the project aims to reduce environmental impact and enhance resource utilization. One obstacle to improving ELV management is the lack of specialized tools for efficient disassembly. While vehicle assembly has advanced with specialized tools, disassembly remains relatively simple, lacking tools to expedite the process. Developing a dedicated tool for vehicle disassembly can help reduce pollution caused by defunct vehicles. ELV batteries contain hazardous materials that can cause environmental pollution and safety hazards if mishandled. Current removal methods are labor-intensive and often inefficient, contributing to delays and increased costs. The lack of a dedicated, adaptable tool further complicates the process, increasing the risk of accidents and hindering efforts to streamline operations. Addressing these challenges requires innovation in battery removal and disposal methods. Developing specialized tools that can adapt to various battery designs and sizes will significantly improve the efficiency and safety of the removal process, contributing to a greener and more sustainable future. The primary objective of the project is to design and construct a portable tool for efficient ELV battery removal. This involves identifying design criteria, suggesting designs based on these criteria, and analyzing and fabricating the tools. The scope includes analyzing current challenges in the depollution process, identifying requirements for a portable and user-friendly tool, researching suitable materials, creating design prototypes, building a working prototype, and performing rigorous testing. Efficient ELV management is crucial for minimizing environmental impact, preserving resources, and promoting a circular economy in the automotive industry. Developing a portable battery removal tool for ELVs is a significant step in this direction, focusing on handling batteries in conventional internal combustion engine automobiles. By ensuring proper waste disposal and enhancing resource utilization, efficient ELV management supports environmental protection goals and fosters sustainable practices in the automotive industry.

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