System for identifying and duplicating master keys

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 for 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; one or more optical path components that direct a light beam along the minor key axis; one or more apparatus that imparts relative motion along the major key axis between the light beam and the master key such that the light beam scans along the major key axis; a detector that receives at least a portion of the light beam; a processor that receives a signal from the detector as the light beam scans along the major key axis and generates bitting information usable for duplicating the master key; and a camera configured to capture an image of the distal end of the master key, wherein the image is usable for identifying a proper key blank for duplicating the master key.

2. The system of claim 1, 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, and wherein the detector receives the portion of the light beam that traverses the key blade.

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

4. The system of claim 1, further comprising a laser for generating the light beam.

5. A method for duplicating a master key comprising: receiving and positioning a master key, wherein the master key defines a major key axis, an intermediate axis along which a key blade variably extends, and a minor key axis along a key thickness; generating a light beam and directing the light beam along the minor key axis; imparting relative motion along the major key axis between the light beam and the master key such that the light beam scans along the major key axis; determining bitting information for the master key based on a detection of at least a portion of the light beam; and capturing an image of the distal end of the master key, wherein the image is usable for identifying a proper key blank for duplicating the master key.

6. The method of claim 5, further comprising: generating a detection signal versus time based on the detection of at least a portion of the light beam, the detection signal verses time corresponding to a height of the key blade along the intermediate axis; and using the detection signal versus time to determining the bitting information.

7. The method of claim 5 wherein receiving and positioning the master key includes affixing the master key in a stationary configuration.

8. The method of claim 5 wherein generating the light beam includes activating a laser.

Description

BRIEF DESCRIPTION OF THE FIGURES

(1) FIG. 1A is an isometric view of an exemplary master key.

(2) FIG. 1B is a side view of an exemplary master key.

(3) FIG. 1C is a cross sectional view of an exemplary master key illustrating the keyway.

(4) FIG. 2 is a schematic plan view of an exemplary system 20 utilized for analyzing and duplicating a master key.

(5) FIG. 3 is a side view depicting a light beam partially traversing the blade of a master key.

(6) FIG. 4 is a schematic plan view of an exemplary system 20 utilized for analyzing and duplicating a master key.

(7) FIG. 5 is an electrical block diagram of certain components of a system 20 utilized for analyzing and duplicating a master key.

(8) FIG. 6 is a flowchart representation of an exemplary embodiment of a method of duplicating a master key using the system depicted in FIGS. 2, 3, 4, and 5.

(9) FIG. 7 is a flowchart representation of an alternative embodiment of a method of duplicating a master key using the system depicted in FIGS. 2, 3, 4, and 5.

(10) FIG. 8 is a schematic plan or top view of a certain components of an alternative system 20 utilized for analyzing and duplicating a master key.

DETAILED DESCRIPTION

(11) FIGS. 1A, 1B, and 1C are isometric, side, and cross sectional views of an exemplary master key 2 to be analyzed for purposes of duplication. According to this description, a master key 2 is any key that a user or customer desires to duplicate such as a house key, a key to a storage unit, a key to automobile, or any other key that mechanically opens or closes a lock.

(12) To illustrate master key 2, three mutually orthogonal axes X, Y, and Z are defined. Minor key axis X is defined along the thickness of master key 2. Major key axis Y is defined along the longest axis of master key 2. Head 4 and distal end 6 of master key 2 are disposed along major key axis Y. Intermediate key axis Z is the defined as the direction along which key blade 8 variably extends.

(13) Master key 2 is uniquely defined by various factors including a (1) keyway 10, and (2) bittings or teeth formed into key blade 8. Keyway 10 is defined by a cross section 10 of master key 2. The keyway 10 has features such as channels 12 and ridges 14 that allow the master key 2 to slide into a particular lock. The channels 12 and ridges 14 define a variable extent of a portion of key blade 8 along minor key axis X.

(14) Key blade 8 extends variably along intermediate axis Z. The variable extent of key blade 8 defines features such as key teeth 16. The variable extent of key blade 8 defines the bitting of master key 2. The bitting of master key 2 determines which specific lock master key 2 can unlock and lock.

(15) FIG. 2 is a schematic representation of an exemplary system 20 for analyzing a master key 2 to be duplicated. System 20 defines an optical path 22 along which a light beam 24 travels between a light source 26 and a detector 28. The light beam 24 traverses and overlaps a portion of key blade 8. An amount of light that reaches detector 28 is a function of the height of key blade 8 along the intermediate key axis Z. System 20 imparts a relative motion along major key axis Y between light beam 24 and master key 2. In doing so the detector 28 receives a variable amount of light versus time that corresponds to the extent of key blade 8 along intermediate key axis Z.

(16) The optical path 22 is defined or formed by a number of optical path components 23. The optical path components 23 can include one or more of a light source 26, a detector 28, a beam shaping component 30, and beam directing components 32 and 34. In an exemplary embodiment the light source 26 is a laser. Detector 28 is a position sensitive detector (PSD) 28. Beam shaping component 30 is a slit 30. Optical path components 23 can also include a cylindrical lens 31 for collimating the light beam 24. Beam directing components 32 and 34 include a first beam directing component 32 and a second beam directing component 34. The first beam directing component 32 receives the light beam 24 from light source 26 and redirects the light beam 24 toward the key blade 8. The second beam directing component 34 receives the light beam 24 from the key blade 8 and redirects the light beam 24 toward the detector 28. Beam directing components 32 and 34 can be mirrors 32 and 34 respectively. In an alternative embodiment beam directing components 32 and 34 can be prisms 32 and 34 respectively.

(17) According to a particular embodiment light source 26 is a laser that generates beam 24 that travels in a Y direction along the major key axis Y. Light beam 24 first encounters slit 30 that reduces the cross-sectional area of light beam 24 and forms a beam having a cross section that is elongate along intermediate key axis Z and otherwise narrowed orthogonally to the direction of travel. Next, the light beam 24 encounters first mirror 32 that deflects light beam 24 from the Y direction to the +X direction along the minor key axis X. Light beam 24 then impinges upon key blade 8 which over which a portion of the light beam 24 is able to traverse and to continue along in the +X direction. Next, light beam 24 encounters second mirror 34 which deflects light beam 24 from the +X direction to the +Y direction. Light beam then travels to detector 28.

(18) Detector 28 is a position sensitive detector (PSD) 28. PSD 28 receives light beam 24 and generates a signal that is related to a location ZC of a centroid along intermediate axis Z of the light beam 24 that has traversed key blade 8. In one embodiment the PSD 28 outputs two signals that are processed in order to determine the centroid Z-axis coordinate ZC. The centroid Z-axis coordinate ZC will tend to linearly increase with the height of key blade 8 over which light beam traverses. Thus the value of ZC over time can be used to compute the profile or bitting of master key 2.

(19) A side view of a portion of system 20 is illustrated in FIG. 3 with emphasis on the effect of key blade 8 upon light beam 24. Mirror 34 is eliminated from FIG. 3 for illustrative simplicity. Light beam 24 travels along direction 36 and partially impinges upon key blade 8. Only an upper portion of light beam 24 traverses key blade 8 because key blade 8 blocks a portion of light beam 24. The amount of light beam 24 that traverses key blade 8 is a function of the extent of key blade 8 along intermediate key axis Z. PSD 28 generates an output signal that is a function of the amount of light received past key blade 8. Thus the output signal of PSD 28 varies with the vertical extent of key blade 8 along intermediate axis Z. The output signal of PSD 28 is processed to determine the centroid coordinate ZC of the light beam 24 that traverses the key blade 8. As the key blade extends farther in the +Z direction the centroid coordinate ZC of the light beam 24 that traverses key blade 8 has a correspondingly increased Z-value.

(20) Referring to FIGS. 2 and 3, the function and advantage of slit 30 is apparent. Slit 30 reduces the width of light beam 24 along the Z and Y axes just before the light beam reaches key blade 8 (after first mirror 32). After the light beam 24 has reflected from mirror 32 the width of the light beam 24 is reduced along the major key axis Y while still relatively wide along the intermediate key axis Z as the light beam 24 partially traverse the key blade 8. The reduction of light beam 24 width along the major key axis Y has the effect of increasing the resolution of system 20 which enables a more accurate measurement of key bitting. At the same time, the wider light beam 24 along the intermediate key axis Z increases the range of extent of key blade 8 along the intermediate key axis Z that can be measured.

(21) In one embodiment the light beam 24 has a width along the intermediate key axis Z that is in a range of 5 millimeters to 10 millimeters. In a more particular embodiment the width of light beam 24 along the intermediate key axis Z is in a range of 5 millimeters to 7 millimeters. In one particular embodiment the width of light beam 24 along the intermediate key axis Z is 6 about millimeters. This will generally accommodate keys having a blade width measured along intermediate key axis Z of up to 5 millimeters. Minimizing the width of the light beam 24 along the intermediate key axis 8 helps to maximize a sensitivity to the height of blade 8 along intermediate key axis 8. Other light beam widths along intermediate key axis Z may be utilized depending on the expected widths of key blade 8 along intermediate axis Z. In an exemplary embodiment the with of the beam along intermediate key axis Z just exceeds the maximum expected key blade width.

(22) In one embodiment the light beam 24 has a width along the major key axis Y that is less than 1 millimeter. In another embodiment the light beam 24 has a width along the major key axis Y that is less than 0.5 millimeter. In a further embodiment the light beam 24 has a width along the major key axis Y that is about 0.25 millimeter.

(23) Referring back to FIG. 2 the master key 2 is held in a stationary position by a clamping mechanism 38. System 20 also includes moveable stage 40 that is configured to linearly translate along key major axis Y. Affixed or mounted to moveable stage 40 are optical path components including laser 26, mirrors 32 and 34, and PSD 28. Thus, the motion of moveable stage 40 defines and imparts the motion of optical path 22. The motion of stage 40 along major key axis Y determines the relative motion between light beam 24 and key blade 8 whereby the light beam 24 scans along key blade 8. The scanning of light beam 24 along key blade 8 results in a light beam 24 whose cross sectional area varies with time reaching PSD 28. The scanning of light beam 24 along key blade 8 also results in a light beam 24 that traverses key blade 8 and reaches PSD 28 whose centroid coordinate ZC varies with time. The time variation is a function of height of key blade 8 along intermediate key axis Z. PSD then outputs a time varying signal that is indicative of or correlates with the profile of key blade 8 along intermediate axis Z.

(24) FIG. 4 is a schematic representation of system 20 to illustrate a subsystem including light sources 42 and camera 44. Light sources 44 can be light emitting diodes (LEDs) 42 that are positioned to illuminate a surface of distal end 6 of master key 2. Camera 44 receives light generally reflected in the +Y direction from distal end 6 to provide an image that represents the keyway 10 (see FIG. 1C). The resultant image may then be used to determine a key blank having the proper keyway for duplication of master key 2. In one embodiment light sources 42 and camera 44 are mounted to moveable stage 40. In another embodiment light sources 42 are fixed and camera 44 is mounted to moveable stage 40. In yet another embodiment light sources 42 are fixed and camera 44 is configured to translate independently of moveable stage 40.

(25) FIG. 5 depicts an exemplary electrical block diagram of circuitry and various components of the system 20 previously described with respect to FIGS. 2, 3, and 4. System 20 includes a main controller board (PCBA) 50 that is coupled to various system components and to a computer 52. It is to be understood that certain components of FIG. 5 have interconnections that for purposes of simplicity are not illustrated. Communication between PCBA 50 and computer 52 can be accomplished via a universal serial bus (USB) port 54. Computer 52 sends control commands to PCBA 50 and receives data from PCBA 50 that is usable to determine a proper key blank and for machining key blade 8 to provide a duplicate of master key 2. In one embodiment PCBA 50 is mounted to stage 40 and is mechanically coupled to PSD 28 as is depicted in FIG. 3.

(26) PCBA 50 includes a laser driver 56 for providing power to laser 26. PCBA also includes a microcontroller 58 that receives a signal originating from PSD 28 that is indicative of an amount of light traversing key blade 8. An analog signal from PSD 28 is amplified by amplifier 57 and then digitized by analog to digital converter 59 before reaching microcontroller 58. Microcontroller 58 processes the digital signal from analog to digital converter 59 and sends information to computer 52 that is indicative of the height of key blade 8 along intermediate key blade axis Z via the USB port 54.

(27) In the illustrative embodiment sensor 28 outputs two analog signals. The amplified and digitized versions of the two signals are received by microcontroller 58. The two signals are processed by microcontroller 58 to determine a position coordinate ZC of a centroid of light beam 24 that has traversed key blade 8.

(28) PCBA 50 includes a clamp driver 60 for operating clamping mechanism 38. In the illustrative embodiment clamping mechanism 38 includes vertical clamp 38V and horizontal clamp 38H for clamping master key 2.

(29) PCBA 50 includes a motor driver 62 for controlling a stepper motor 64 for translating moveable stage 40 along major key axis Y. Motor driver receives positional feedback from encoder 66.

(30) PCBA 50 includes an LED driver 68 for driving LEDs 42 for illuminating the distal end 6 of master key 2. Camera 44 provides information to computer 52 that is indicative of an end image received from distal end 6 of master key 2.

(31) FIG. 6 is a flowchart depicting an exemplary process 100 for machining a duplicate of master key 2. For this exemplary embodiment the system 20 described with respect to FIGS. 2, 3, 4, and 5 is utilized. For this embodiment various optical path components 23 including laser 26, PSD 28, first mirror 32, and second mirror 34 are affixed to moveable stage 40 which moves linearly along the major key axis Y.

(32) According to initial condition 102, the moveable stage is at a home position which is as far to the Y position as possible. According to step 104, a master key 2 is received in clamping mechanism 38 and the process 100 is started. Also according to step 104 the master key 2 is clamped by clamping mechanism 38.

(33) According to step 106 the stepper motor 64 is activated to scan moveable stage 40 in the +Y direction along the major key axis Y whereby the light beam 24 is moved or scanned toward the distal end 6 of master key 2. As the light beam 24 is scanned the bitting information is captured according to step 108. As part of step 108 the vertical extent of light beam 24 along intermediate key axis Y reaching PSD 28 is varied according to the extent of key blade 8 along intermediate axis Y. This variation results in a varying output signal from PSD 28 that is received and processed by microcontroller 58. Microcontroller 58 then generates and transmits information indicative of the bitting of master key 2 to computer 52.

(34) According to step 110 a Y coordinate of the distal end 6 of master key 2 is determined according to the signal generated by PSD 28. When the light beam 24 passes the distal end 6 the computed centroid of light beam 24 along Z will be a minimum and a constant. The Y-position received from encoder 66 when the signal is first maximized will then be that of the distal end 6 of the key.

(35) According to step 112 the system 20 uses the Y-position of distal end 6 to determine the proper positioning of camera 44 to focus on the distal end 6 of master key 2. Also according to step 112 the camera 44 is moved into the position for focusing on distal end 6.

(36) According to step 114 camera 44 captures an image of the distal end 6 of master key 2. According to step 116 the image of distal end 6 and the bitting information (captured in step 108) are used to determine and enable a selection of a proper key blank. According to step 118 the selected key blank is machined using the bitting determined from step 108.

(37) According to step 120 the master key 2 is released and removed from clamping mechanism 38. Also as part of step 120 the movable stage 40 moves in the Y direction and back to the home position described with respect to step 102.

(38) FIG. 7 is a flowchart depicting an alternative exemplary process 150 for machining a duplicate of master key 2. For process 150 the system 20 described with respect to FIGS. 2, 3, 4, and 5 is utilized. For this embodiment various optical path components 23 including laser 26, PSD 28, first mirror 32, and second mirror 34 are affixed to moveable stage 40 which moves linearly along the major key axis Y.

(39) According to initial condition 152 moveable carriage starts at a home position that is as far in the +Y direction along the major key axis Y as possible. In this position the light beam 24 will not intersect a master key 2 having the largest distal dimension Y(distal end 6) along major key axis Y.

(40) According to step 154, a master key 2 is received in clamping mechanism 38 and the process 150 is started. Also according to step 154 the master key 2 is clamped by clamping mechanism 38.

(41) According to step 156 the stage begins to move in the Y direction while camera 44 attempts to focus on the distal end 6 of master key 2. According to step 158 camera 44 detects the end of master key 2 and determines a proper position of movable carriage 40 for proper focusing of camera 44 upon the distal end 6. According to step 160 the camera 44 captures an image of distal end 6 of master key 2. According to step 162 the computer 52 utilizes the image from step 160 to identify and enable selection of a proper key blank for duplication of master key 2.

(42) Also according to step 158 system 20 (computer 52 included) determines a Y-location of distal end 6 of master key 2. Thus the system can move quickly to an optimal position according to step 164. According to step 166 light beam 24 is scanned along key blade 8. Also according to step 166 PSD 28 receives the variable light beam 24 versus time and outputs a signal to microcontroller 58. Microcontroller 58 provides information to computer 52 indicative of the bitting of master key 2. Thus the bitting information of master key 2 is captured according to step 168.

(43) According to step 170 a new key is machined from the selected key blank. According to step 172 the master key 2 is unclamped and the carriage is returned to a retraced (+Y) home position as it started according to 152.

(44) Other variations are possible. For example, the image obtained from step 160 and the bitting information from step 168 may be utilized to select the proper key blank.

(45) An exemplary embodiment of system 20 has been described in which a motion of light beam 24 along major key axis Y is imparted by the motion of optical path components 23 mounted or affixed to moveable stage 40. An alternative embodiment of system 20 is depicted as system 20 in FIG. 8 in which optical path components 23 are stationary during an optical scan of master key 2. Stationary optical path components 23 cause light beam 24 to scan along major key axis Y of master key 2 without motion of the stationary optical path components 23.

(46) System 20 includes master key 2, clamping mechanism 38, laser 26, slit 30, lens 31 (not shown in FIG. 8), detector 28, and camera 44 that are all similar to like-numbered elements described with respect to FIG. 2. System 20 also includes scan module 200, first curved mirror 202, and second curved mirror 204. Scan module 200 can take on a number of forms. One example is a rotating galvanometer mirror. Another example is a rotating polygon mirror.

(47) In the exemplary embodiment of FIG. 8, scan module 200 causes light beam 24 to rotate back and forth as indicate by the dashed lines. Curved mirror 202 serves to change the path of light beam 24 such that it linearly scans across blade 8 of master key 2. Curved mirror 204 then causes light beam 24 to converge upon detector 28. The output from detector 28 in FIG. 8 is similar to that described with respect to FIG. 2.

(48) Other variations of stationary optical components 23 are possible to eliminate a need for mechanical motion during scanning. For example, the scan module 200 can be designed to impart linear motion of light beam 24. Reflective optics for conveying the scanning beam to the key blade 8 and the detector 28 would then be selected to accommodate the linear scanning motion of light beam 24 for such an embodiment.

(49) Referring back to FIG. 2, an exemplary embodiment has been described in which clamping mechanism 38 is fixed while light beam 24 moves across key blade 8. Alternatively, system 20 may be designed in which clamping mechanism 38 translates along major key axis Y while light beam 24 is stationary. This will result in essentially the same output from detector 28.

(50) Thus, the specific embodiments and applications thereof described above are for illustrative purposes only and do not preclude modifications and variations encompassed by the scope of the following claims.