Duplicate Key Blade Scanning With Triple-Laser 3D Decoding
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Solution Overview
Problem
Existing key duplication systems face challenges in accurately capturing and decoding information from vehicle keys due to issues like non-ideal positioning, pitch angles, and perspective effects, leading to incorrect measurements and incomplete 3D profiles.
Innovation Solution
A triple-laser scanning process is employed to correct targeting and capture high-quality 3D profiles of key blades, combined with a decoding method that simulates virtual lock pins to determine accurate bitting information, allowing for precise cutting of duplicate keys based on OEM specifications or 'by trace' if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single laser scanning process is used to capture key information, then the system is simple and fast, but measurement precision deteriorates due to pitch angles and perspective effects
Solution Approach 1:
The scanning process is divided into multiple sequential laser scans instead of a single scan. The first scan captures initial key information and determines pitch angle, the second scan corrects for pitch angle effects, and the third scan captures final accurate measurements. This segmentation allows each scan to focus on specific measurement aspects, improving overall precision without requiring complex simultaneous multi-sensor systems.
Solution Approach 2:
The first laser scan performs preliminary measurement to determine the pitch angle of the key blade. This preliminary information is then used to calculate correction factors that are applied in subsequent scans. By performing this preliminary characterization action first, the system can compensate for positioning errors in later scans, improving measurement accuracy without requiring perfect initial positioning.
2Ease of operation
If the key blade is not positioned at the exact calibrated distance from the camera, then operation flexibility is improved, but measurement precision deteriorates due to perspective distortion and blurriness
Solution Approach 1:
The system uses the first laser scan to obtain feedback information about the actual position and pitch angle of the key blade. This feedback is then used to calculate correction factors that are applied in subsequent scans. The iterative feedback loop allows the system to adapt to actual positioning conditions rather than requiring perfect pre-positioning, maintaining measurement precision while improving operational flexibility.
Solution Approach 2:
The system changes scanning parameters dynamically based on measured key position. Instead of using fixed scanning parameters calibrated for a specific distance, the system adjusts scanning parameters (such as laser targeting and image capture settings) based on the actually measured key position and pitch angle from the first scan, compensating for positioning variations.
3Manufacturing precision
If traditional grinding wheel approaches are used for key cutting, then manufacturing simplicity is maintained, but manufacturing precision deteriorates for modern milled keys
Solution Approach 1:
The patent replaces traditional mechanical grinding wheel cutting with computer-controlled milling cutting. The highly accurate 3D profile measurements obtained through the triple-laser scanning process are used to guide precision milling cutters that can replicate complex modern key blade geometries with much higher accuracy than grinding wheels, justifying the increased device complexity through superior manufacturing precision.
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
This approach ensures accurate reproduction of key blades, addressing alignment and angle issues, and provides reliable duplicate keys that match the original in both shape and functionality, even for complex vehicle 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.