Duplicate Key Imaging Flipper for Bulky Non-Flat Keys
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Solution Overview
Problem
Key cutting machines face challenges in accurately imaging and positioning non-flat master keys due to their bulky designs, leading to errors in data capture and inefficient storage and retrieval systems, which result in incorrect key duplication and customer frustration.
Innovation Solution
A system that includes a flipper mechanism for accurate positioning of non-flat keys, a honeycomb storage matrix for automated key selection and inventory management, and a gripper mechanism for handling various key types, along with a packaging system that allows for efficient storage and retrieval of keys, enabling single transaction processing for multiple orders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If flat scanning surface is used for key imaging, then simple structure is achieved, but imaging accuracy of non-flat keys deteriorates
Solution Approach 1:
The patent employs a movable flipper mechanism that can dynamically change the scanning surface orientation. The flipper rotates between horizontal and vertical positions, allowing the system to adapt its structure dynamically based on the key type being scanned, thus maintaining both structural simplicity and imaging accuracy
Solution Approach 2:
The patent introduces a vertical scanning dimension by rotating the flipper to a vertical position. This dimensional change allows non-flat keys to be scanned from the side rather than from above, eliminating imaging errors caused by key thickness while maintaining a relatively simple overall structure
2Adaptability or versatility
If multiple key types are stored for duplication, then customer service coverage is improved, but storage and retrieval complexity increases
Solution Approach 1:
The patent divides the storage system into modular key holder units that can be individually managed. Each unit stores specific key types and can be independently accessed by the gripper mechanism, reducing the complexity of managing diverse key inventories while maintaining broad service coverage
Solution Approach 2:
The system employs an automated gripper mechanism that autonomously selects and retrieves the appropriate key type based on the duplication request. This self-service capability eliminates manual intervention in the storage and retrieval process, reducing operational complexity despite handling multiple key types
3Ease of operation
If manual key positioning is used, then simple operation is achieved, but positioning accuracy of non-flat keys deteriorates
Solution Approach 1:
The flipper mechanism dynamically adjusts its orientation based on the key type being positioned. For non-flat keys, it automatically rotates to the vertical position, providing accurate positioning without requiring manual adjustment while keeping the operation simple for the user
Solution Approach 2:
The flipper acts as an intermediary between the user's simple placement action and the precise positioning requirement. It automatically orients the key correctly on the scanning surface, mediating between ease of operation and positioning accuracy
Data Source
AI summary
A “flipper” presents a key-receiving and positioning component to a user having a known key type that is not conducive to laser scanning or the like on a flat imaging glass plate; 2) a key storage system comprising a matrix of known storage cells and an automated system used to automatically identify, locate and select keys stored in the storage matrix; 3) enhanced packaging formats for storing a variety of keys for efficient picking and placing of the keys for cutting operation and a “Faux Key Blade” for use in packaging of smartkeys and OBD Dongle products that do not have a key blade incorporated therein or is a detachable feature; 4) a gripping or grabbing mechanism adapted to effectively “pull” a desired duplicate key from a known storage spot or cell among a key product storage matrix of storage cells; and 5) an effective “escrow” of collective delivery system to deliver multiple items or key products in one transaction as opposed to piecemeal transactions.