Low Cost Braille Embosser
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- Imogene Doyle
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1 Low Cost Braille Embosser Design Team Benjamin Braggins, Molly Brown Patrick Cleary, Jeffrey Witkowski Design Advisor Prof. Gregory Kowalski Abstract Many braille readers are restricted from printing personal documents and s by the high cost of braille printers. Printing braille is actually embossing the paper and requires a special embosser. Braille embossers cost from $2000 to $6000 whereas personal inkjet printers cost from $35 to $400. A new design for a mechanical assembly and its interface with electronic controls in order to emboss braille is outlined in this report. Cost reduction while maintaining braille quality is the major priority. The entire mechanical assembly is designed to retrofit an existing inkjet printer with feasible modifications to the inkjet printer and requiring minimal retrofit assembly. The mechanical assembly, additional electrical components and their integration into the printer are outlined in this report. The individual dots embossed on the paper are made by applying force to pins in a 2x3 pin pack. This design is unique because it regards each braille character as two independent columns of three dots as opposed to an entire 2x3 matrix of six dots thus drastically reducing the number of possible combinations of dots. Every permutation for a column of dots, a half braille character, is cut around the circumference of a wheel. Two wheels are independently rotated to form a braille character which then causes the appropriate configurations of pins to emboss the paper. A prototype is using an Epson NX-415 inkjet printer is completed and printed samples given to the National Braille Press for review.
2 The Need for Project Current braille embossers cost The National Braille Press estimates that 2% of the population of $2000+ make everyday printing the United States is blind. Despite advancements in audio interfacing ( s and documents) and other technologies, the blind community still relies largely on impractical for the blind braille for communication and documentation. Printing s, forms community. and reports for personal use as well as distribution of material is critical for the blind community and their integration into society. It is important that schools be able to afford to accommodate blind students and offices to engage blind professionals. Current products on the market retail for at least $2000, a financial burden that institutions and blind individuals often cannot bear. The Design Project Objectives and Requirements Design a braille printer that Design Objectives produces quality text at a lower The goal of this project is to produce a low cost braille embosser. cost than products currently The system must be easy to manufacture and maintain. Since it is available retrofit to an existing inkjet printer, the easiest installation requires a self-contained braille mechanism. The quality of the printed material must be comparable to what is produced by current embossers while satisfying braille dot requirements set by the Library of Congress standards. The production price of a complete braille embosser must be much less than what is currently on the market to meet the needs of the blind community. Design Requirements The printer must emboss standardized braille with accuracy and repeatability. The system must deliver the embossing force required for standard braille paper of 6 N per dot. Using this force, it must take no longer than 20 minutes to print a page. The embosser must not exceed the current standard of 60 decibels during operation. Finally, the final product should cost no more than $300. Design Concepts considered Two approaches were Two different types of designs were selected as possible solutions considered, viscous ink and a to satisfy all requirements. Viscous ink provided a chemically based rotating wheel. Development of process as opposed to the mechanical method of an eight-sided the rotating wheel resulted in the patterned wheel. final design. Viscous Ink Viscous ink was considered because it takes few additional parts and adjustments to switch from regular ink to a textured adhesive.
3 2 stepper motors Side by side wheels Recommended Design Concept Computer controlled stepper motors align wheels to punch pins paper which deforms into the back plate to emboss the correct dot geometry. However, it was found that this design does not satisfy all design requirements. The final printed braille could not be held to any standard of repeatability or quality. Many outside factors would contribute to inconsistency including temperature, humidity, and paper type. Furthermore, standard braille is embossed paper not an adhesive on the surface of paper; a tactile difference undesirable to a braille reader. Braille Pointed Star The second approach is more mechanical and eventually evolved into the final design used on the prototype. The fundamental concept breaks a braille character into two separately produced halves. Each possible permutation for a half character is embossed on a point on the metal star. The star would be rotated until the appropriate point is aligned above the page and then pressed into the paper. Two rotationpress sequences produce a single character. This design requires detailed components and the removal of inaccessible components in the inkjet printer and therefore does not satisfy manufacturing requirement. Vertical Octagon Wheel By taking the eight, half-letter permutations and aligning them around the circumference of an octagon instead of a star, two octagons side by side can now print a whole letter at a time. This design is compact, fitting within the ink cartridge tray that already exists within the printer. Also the printers control system for the ink cartridge tray could be used to reduce control system adjustments. Each octagonal wheel would be rotated by a stepper motor to change the braille characters. The wheel-motor assembly would be actuated into the page using an eccentric driven by a DC motor. This design addresses all requirements but printing would be interrupted due to the clearances within the inkjet printer. Design Description The recommended design removes the original components of the ink cartridge tray and replaces them with a mechanical assembly. The resulting braille embossing method involves three operations managed by one control system. These are braille letter selection, linear actuation, and embossing. Braille Letter Selection
4 Linear actuation of a pin, forming the paper into the back plate Two eight-sided embossing wheels rotate in a plane parallel to the paper and are controlled individually by stepper motors. Each embossing wheel contains a series of holes along its circumference that corresponds to all possible combinations of one-half a braille letter. Dots that are not in the selected braille character correspond to the pins located below these holes whereas dots made are from the pins that contact the solid portion of the wheel. Hall effect sensors track the distance from a home location for each wheel to keep the system aligned. Linear Actuation Once the wheels are aligned to print the correct letter, they are driven towards the page by an eccentric shaft connected to a DC motor. The shaft is placed through the frame of the mechanical assembly and is supported by a sleeve bearing on the opposite side of the motor. The eccentricity of the shaft is one millimeter causing a linear vertical displacement of two millimeters. The DC motor delivers a torque of 3200 g-cm, which exceeds the minimum force needed to emboss all six dots in a single actuation. Embossing Once actuated downward, the wheels contact a matrix of pins that are either pressed into the page by the DC motor force or pass through the holes in the wheels and do not contact the paper. These pins are constrained in a housing where they do not interfere with realigning the wheels for the next letter and are spring loaded so that they return to their original position after embossing the paper. The pin point is rounded to prevent puncturing the paper. The paper rests on a stationary back plate on which columns of three dimples are cut. As the rounded pin points are pressed into the back of the paper, these dimples form the correct surface of the braille dots from the front of the paper. Control Systems Motor drivers and control code were written to send signals to the stepper motors indicating the angle that will align the proper letter and to run the DC eccentric motor at a constant speed. The existing inkjet motors were adjusted to track the mechanical assembly across the page as it embosses a line of braille and feed the page down at the end of a line. Hall effect sensors read magnets on the wheels to provide
5 Test setup for force requirement Financial Issues The prototype mechanical and electrical control assembly costs $ This will be reduced by larger scale manufacturing. feedback on the position of the stepper motors. The existing optical feedback system is used in controlling the motion tracking across the page. Experimental Investigations Prior to material and motor selection, the force required to print braille was determined using a balance device. A mass was placed at the center of the balance and the force was then divided between the support end and the embossing end of the balance. 75 total samples were taken using 20, 32, and 80 weight paper. The maximum weight required was 1.5 kilograms for a single dot on the National Braille Press 80 weight paper. Test pages made using the prototype assembly will be given to blind readers at the National Braille Press to verify the quality. Analytical Investigations The DC motor responsible for linear actuation uses a shaft having an eccentric of 1mm and must deliver a downward force of 36 N. The eccentric axis is directly above the pins, eliminating additional moments and maximizing the available embossing force. The required torque was calculated to be 900 g-cm. Key Advantages of Recommended Concept This embossing system requires minimal additions to an existing inkjet printer making it the most cost-effective method to print braille text from a personal computer. Having a simple mechanical design minimizes opportunity for malfunction and allows for inexpensive manufacturing and assembly. The inkjet printer is already equipped with a paper feeding system and carriage that tracks across the page. Custom circuitry and motors can be added to make the adjustments from printing ink to embossing braille. Together the circuitry and mechanical assembly can produce the same quality printer braille as current expensive embossers. The total cost of the prototype is $ The most expensive part is the housing which was made from sheet metal for a single prototype but could be injection molded out of plastic for less on a larger scale. Results from finite element analysis of the part confirm plastic as a material selection. The additional circuitry could also be silkscreened onto a single custom board, further reducing the cost of
6 Recommended Improvements larger scale production. The final braille embosser will cost the amount of the inkjet printer plus the mechanical assembly and circuitry. Further electrical controls The prototype is estimated to print one page of braille in twenty development to make the retrofit minutes. This is due to the speed of the DC motor and the eccentric assembly universal to inkjet shaft. Motors with more torque that are not physically too large cost printers. significantly more, however, with overall costs reduced on a larger scale, a more expensive motor could be affordable. With extensive research into personal computer to printer protocols, it may be possible to create a single electrical control system and mechanical assembly to fit any inkjet printer. The size of the mechanical assembly is constrained by the braille letter geometry but the entire assembly can be made smaller by consolidating the control systems circuitry. Further development could be directed towards maximizing the amount of mechanical and electrical assembly that can be done before the component is added to the printer. This minimizes the retrofit process for the user.
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