Duplicate Key Scanning With Triple-Laser Bitting Decoding
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Solution Overview
Problem
Existing key copying systems struggle to accurately capture and decode information from master keys, particularly vehicle keys, due to issues with positioning, wear, and damage, leading to errors in bitting patterns and key blade dimensions.
Innovation Solution
A triple-laser scanning process is employed to capture a high-quality 3D profile and distortion-corrected 2D outline of the key blade, correcting for positioning errors and allowing for accurate decoding of key bitting information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single laser scanning process is used to capture key information, then the scanning process is simple and fast, but the measurement accuracy deteriorates due to positioning errors and image distortion
Solution Approach 1:
The scanning process is divided into multiple sequential laser scanning operations (first, second, and third scans) rather than a single scan. Each scan captures specific portions or aspects of the key blade at different positions, allowing the system to overcome positioning errors and distortion by combining multiple partial measurements into a complete accurate profile.
Solution Approach 2:
The system transitions from a single 2D scan to multiple scans that effectively create a 3D understanding of the key blade geometry. By scanning at different positions and combining the data, the system reconstructs the true 3D shape of the key blade, compensating for perspective distortion and positioning errors that affect single-plane scanning.
2Measurement precision
If multiple laser scanning lines are used to capture complete key information, then the measurement accuracy improves, but the scanning time and system complexity increase
Solution Approach 1:
The first and second laser scans are performed as preliminary actions to establish key positioning information and determine the pitch angle of the key blade. These initial scans prepare the system by identifying critical geometric features and calculating orientation parameters, which then inform the positioning and execution of the third scan that captures the final bitting pattern data.
Solution Approach 2:
The scanning process uses periodic laser line projection at specific intervals along the key blade. Rather than continuously scanning, the system projects laser lines at discrete, strategically chosen positions (first position, second position, third position) and combines these periodic measurements to build the complete key profile, reducing total scan time while maintaining accuracy.
3Ease of operation
If the key blade is not perfectly positioned on the scanning surface, then the ease of operation improves, but the measurement accuracy deteriorates due to perspective distortion and blurriness
Solution Approach 1:
The system uses feedback from the first and second scans to detect the actual position and orientation (pitch angle) of the key blade on the scanning surface. This feedback information is then used to adjust and correct the positioning for the third scan, compensating for any initial misplacement or perspective distortion that occurred during the flexible key placement process.
Solution Approach 2:
The system changes scanning parameters dynamically based on detected key positioning. The pitch angle calculated from initial scans is used to adjust the laser positioning and image capture parameters for subsequent scans. By adapting scanning parameters to the actual key position rather than requiring perfect initial positioning, the system maintains measurement accuracy while allowing operational flexibility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively addresses the challenges of capturing information from vehicle keys by providing accurate measurements and bitting patterns, ensuring precise cutting of duplicate keys.
Implementation Method 1
targeting a laser and projecting at least one laser line on the master key key blade based at least in part on captured image data
Data Source
AI summary
The present invention generally relates to the field of replicating or copying keys. More specifically, the present invention relates to creating a copy of a master key based on a captured image of the master key by using a laser scanning of the master key and decoding the master key based on the captured image. The present invention identifies a set of target key information based on the image of the master key to provide for the cutting of a duplicate key blade copy using a key scanning and cutting system located at a retail or end location. Additional key information may also be captured along with the image of the master key.