System for identifying and duplicating master keys

• US 9,808,900 B2
• Filed: 06/23/2016
• Issued: 11/07/2017
• Est. Priority Date: 06/26/2015
• Status: Active Grant

• Current Assignee: Hillman Group Incorporated (Hillman Solutions Corp.)
• Original Assignee: Minute Key, Inc. (Hillman Solutions Corp.)
• Inventors: Gardner, Richard L., Cooley, Bradford Shayne, Kortbawi, David
• Primary Examiner(s): STAFIRA, MICHAEL PATRICK
• Application Number:
  US15/191,071
• Publication Number:
  US 20160377418A1
• Time in Patent Office: 502 Days
• CPC Class Codes: B23C 2235/24 Electronic sensors
• CPC Class Codes: B23C 2235/32 Measurement systems
• CPC Class Codes: B23C 2235/41 Scanning systems
• CPC Class Codes: B23C 2260/56 Lasers improving machinability with laser whilst milling B23P25/003
• CPC Class Codes: B23C 2260/76 Sensors
• CPC Class Codes: B23Q 35/00 Control systems or devices for copying directly from a pattern or a master model; Devices for use in copying manually copy milling classified also in B27C5/003
• CPC Class Codes: G01B 11/24 for measuring contours or curvatures
• CPC Class Codes: G01B 5/0018 for measuring key-ways

Abstract

A system for duplicating a master key includes a mechanism for receiving and positioning a master key. The master key defines a major key axis and an intermediate key axis along which a key blade variably extends, and a minor key axis along a key thickness. Optical path components direct a light beam along the minor key axis. The light beam impinges upon the key blade. A portion of the light beam traverses the key blade. A detector receives the portion of the light beam that traverses the key blade. An apparatus imparts relative motion along the major key axis between the light beam and the master key. The light beam scans along the major key axis of the master key. A processor receives a signal from the detector as the beam scans along the major key axis and generates information usable for defining the machining of a duplicate key.

Claims

1. A system duplicating a master key comprising:

a mechanism for receiving and positioning a master key wherein the master key defines a major key axis, an intermediate key axis along which a key blade variably extends, and a minor key axis along a key thickness;

optical path components, that direct a light beam along the minor key axis wherein the light beam impinges upon the key blade such that a portion of the light beam is blocked by the key blade and another portion of the light beam traverses across the major axis of the key blade;

a detector that receives the portion of the light beam that traverses the key blade;

an apparatus that imparts relative motion along the major key axis between the light beam and the master key wherein the light beam scans along the major or key axis of the master key; and

a processor that receives a signal from the detector as the beam scans along the major key axis and generates information usable for defining the machining of a duplicate key.

2. The system of claim 1 wherein the mechanism holds the master key in a fixed location wherein the relative motion is a result of motion of the light beam.

3. The system of claim 1 further comprising a moveable stage configured to move along the major key axis, the optical path components are affixed to the moveable stage wherein the moveable stage is the apparatus that imparts the relative motion along the major key axis between the light beam and the master key.

4. The system of claim 3 further comprising a laser for generating the light beam.

5. The system of claim 4 wherein the optical path components include first and second beam directing components, the first beam directing component redirecting light beam between the laser and the key blade, the second beam directing component redirecting light beam between the key blade and the detector.

6. The system of claim 4 wherein, laser and the detector are affixed to and move with the moveable stage.

7. The system of claim 1 wherein the detector is a position sensitive detector (PSD).

8. The system of claim 1 wherein at least some of the optical path components are stationary and the relative motion is imparted by one or more of (1) motion of the mechanism for receiving and positioning the key and (2) a scan module that imparts motion of the light beam relative to the optical path components.

9. A method of duplicating a master key comprising:

receiving and clamping a master key defining a major key axis, an intermediate key axis along which a key blade variably extends, and a minor key axis that defines a key thickness;

generating a light beam extending along the minor key axis, wherein a portion of the light beam is blocked by the key blade and another portion of the light beam traverses across the major axis of the key blade before reaching a detector;

imparting relative motion along the major key axis between the light beam and the key wherein the light beam scans along the major key axis; and

the detector generating a signal versus time that corresponds to the height of the key blade along the intermediate axis.

10. The method of claim 9 wherein receiving and clamping the master key includes affixing the master key in a stationary configuration.

11. The method of claim 9 wherein a moveable stage configured to move along the major key axis includes optical path components affixed to the moveable stage that direct the light beam wherein the motion of the moveable stage imparts the relative motion between the light beam and the key.

12. The method of claim 11 wherein generating the light beam includes activating a laser.

13. The method of claim 12 wherein the optical path components include first and second beam directing components and further comprising:

receiving the light beam from the laser;

the first beam directing component redirecting the light beam from the laser toward the key blade; and

the second beam directing component redirecting the light beam from the key blade to the detector.

14. The method of claim 13 wherein the first beam directing component is a first mirror and the second beam directing component is a second mirror, the first mirror redirecting the light beam from along the major key axis to the minor key axis, the second mirror redirecting the light beam from along the minor key axis to the major key axis.

15. The method of claim 9 wherein a camera is mounted on a moveable stage and further comprising the camera capturing an image of a distal end of the key.

16. The method of claim 15 further comprising utilizing information from the signal to position the camera relative to the distal end of the key.

17. A system for duplicating a master key comprising:

a mechanism for receiving and clamping a master key in a fixed position, the master key defining a major key axis, an intermediate key axis along which a key blade variably extends, and a minor key axis along a key thickness;

a light source that generates a light beam;

a detector;

a moveable stage configured to move along the major key axis;

optical path components affixed to the movable stage that receive the light beam from the light source and direct the light beam along the minor axis of the key blade such that a portion of the light beam is blocked, by the key blade and another portion of the light beam traverses across the major axis of the key blade and from the key blade to the detector, wherein motion of the moveable stage causes the light beam to scan along the major key axis; and

a processor that receives a signal from the detector and provides information used to machine a duplicate key.

18. The system of claim 17 wherein at least one of light source and detector is affixed to the stage.

19. The system of claim 17 wherein the optical path components include:

a first beam directing component that receives the light beam along the major key axis and redirects the light beam along the minor key axis before the light beam reaches the key blade; and

a second beam directing component that receives the light beam along the minor key axis from the key blade and redirects the light beam along the major key axis before the light beam reaches the detector.

20. The system of claim 17 further comprising a camera mounted to the moveable stage for capturing an end image of the key for identifying a proper key blank for duplicating the master key.