-Caveat Lector- Tests find how much pressure voter must apply to remove chad By Gary Kane Palm Beach Post Staff Writer Saturday, January 13, 2001 BOCA RATON -- Courts and columnists, candidates and consultants wrestled with the question throughout the contentious post-election period. Just what is the difference between a vote and a pregnant chad? Mechanical engineering Professor Jose Villanueva has an answer: about 31/2 ounces of applied pressure. In tests commissioned by The Palm Beach Post, Villanueva, who teaches at Florida Atlantic University, and graduate student Gilmer Viana measured the force required to cast both clear votes and dimpled ballots on the two types of punch-card voting devices used in Palm Beach County. Among their findings: On average, 11 or 12 ounces of pressure will push a stylus through a ballot, detaching a chad. It's slightly easier to pop a chad using a Votomatic than the more-compact Data Punch apparatus. Chads dislodge more easily from the center of the ballot than they do along the top, bottom and sides of the ballot. It takes about the same amount of force to dislodge a chad with a sharp-tipped stylus as it does with a dull-tipped stylus. But the dull tip will generate more hanging chads. The tests also indicated that arguments about chad buildup in the voting devices might have been off-target. Democrats and Republicans squabbled in court over the possibility that some votes were blocked by mounds of chads piling up in the reservoirs at the bottom of Votomatics and Data Punch devices. But Villanueva said his tests showed that chad buildup was more likely to occur above the thin layer of rubber that forms the top surface of the reservoir -- caused by hanging chads becoming dislodged when ballots were removed from the voting device. Most people posses the physical might needed to cast a vote on a punch-card system, the professor said. "A feeble person couldn't," he said. "I imagine some people who live in nursing homes wouldn't have the strength to put 11 ounces of pressure on the stylus." By comparison, tests showed that about 3.6 pounds of pressure are needed to depress the lever on a typical toaster -- about 41/2 times the force needed to vote. To conduct the tests, Villanueva and Viana had to come up with a way to use a low-capacity testing machine to measure the small amount of force needed to dislodge a chad. The machine, which resembles an oversized drill press, is capable of exerting 20,000 pounds of pressure. It's typically used by engineers to test the strength of materials used in manufacturing and construction. Curve on paper shows force The two engineers decided to use a strain gauge, which would be sensitive to low levels of pressure. They attached the stylus to a load cell, a strip of aluminum about the size of a ruler. The strain gauge was fastened to the underside of the load cell, which in turn was attached to the low-capacity testing machine. As the testing machine pushed down on the load cell, the stylus pressed against the paper ballot. The strain gauge sensed the force and emitted a signal, which was then amplified and transmitted to a recorder, which plotted the force on a piece of paper, etching a curve in a manner similar to a polygraph machine. Sample ballots were used in the tests. Manufacturers say the perforations on sample ballots are not as precise as actual ballots and therefore a little more force is required to dislodge the chad. Villanueva and Viana conducted several tests on each voting device. They found that, on average, 11.5 ounces of force pushed the stylus through the ballot in the Votomatic system, whereas 12.8 ounces were needed to do the same on the Data Punch device. County election records show a higher rate of under-votes -- ballots that failed to register a vote when fed through electronic tabulators -- in precincts using the Data Punch system than in precincts using the Votomatics. Tests showed that as little as 6.4 ounces of weight on the stylus will create a dimpled chad. Add 31/2 more ounces, and the chad begins to detach, forming a hanging chad. Chads are easier to dislodge from the center of the ballot than from the outer edges, the tests show. Using the Votomatic, 11.5 ounces applied to the stylus removed chads from the center of the ballot. But 12.5 ounces were needed on average to punch chads from the edges. Villanueva suggested filing off the sharp tip of the stylus to see whether a dull stylus would require more voter muscle in the voting booth. The difference was negligible -- a dull-tipped stylus would require about sixthteen-one hundredths of an ounce more power by the voter. "We did see an increase in hanging chads with the stylus when the point was dull," he said. It's doubtful that dull tips were responsible for the county's post-election headache. The county routinely replaces worn styluses, Elections Supervisor Teresa LaPore said. The engineers discovered that hanging chads often separated from ballots as they are pulled out of the Votomatic and the Data Punch devices. The loosened chads cling to the inside of the apparatus in a tight niche where the paper ballot slides between a plastic screen above and a thin layer of rubber below. The stylus is supposed to push the chad through a narrow slit in the rubber strip. Ideally, the tight rubber slit wipes the stylus clean of chad as the stylus is withdrawn. Clogging problem was known But the engineers found that chad buildup on top of the rubber layer could have frustrated voters by making the ballot harder to punch through, which could account for some of the dimpled chads, Villanueva said. "It's a possible scenario," he said. That same scenario was briefly mentioned during last month's court hearing on Vice President Al Gore's election contest. A voting-device designer testified that he applied for a patent in 1982 to correct a problem with Votomatics -- the area between the plastic template and the rubber tended to clog with chad. Villanueva also noted that dislodging a chad by pushing the stylus through the voting apparatus at a slight angle also requires greater force. 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