Key Duplication Flipper and Storage Matrix for 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
The implementation of 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 formats, along with a packaging system that includes a faux key blade for smart keys without a physical blade, enables efficient key cutting and delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a flat scanning surface is used for imaging keys, then simple device structure is achieved, but non-flat keys cannot be accurately positioned and imaged
Solution Approach 1:
The patent introduces a movable flipper mechanism that can change its position and orientation dynamically. The flipper rotates between a first position (for flat keys) and a second position (for non-flat keys), allowing the scanning surface to adapt to different key types. This dynamic adjustment resolves the contradiction by maintaining simple structure while enabling accurate imaging of both flat and non-flat keys.
Solution Approach 2:
The scanning surface is segmented into multiple positions using the flipper mechanism. The flipper creates distinct scanning planes - a first scanning surface for flat keys and a second scanning surface for non-flat keys. This segmentation allows each surface to be optimized for specific key types, resolving the contradiction between structural simplicity and imaging accuracy for diverse key formats.
2Device complexity
If a single storage location is used for key blanks, then simple storage structure is achieved, but automated selection and retrieval of specific key types becomes inefficient
Solution Approach 1:
The storage system is segmented into multiple storage locations, each dedicated to specific key types or formats. This segmentation enables the automated system to quickly locate and retrieve the correct key blank without searching through all keys, resolving the contradiction between structural simplicity and retrieval efficiency.
Solution Approach 2:
The patent introduces a pick and place mechanism as an intermediary between the storage system and the cutting mechanism. This automated intermediary handles the complex task of selecting and retrieving specific key types based on the master key being duplicated, resolving the contradiction by automating the selection process while maintaining organized storage.
3Ease of operation
If manual key positioning is used, then simple operation procedure is achieved, but positioning accuracy for non-flat keys deteriorates
Solution Approach 1:
The flipper mechanism is designed to automatically position non-flat keys on the appropriate scanning surface. When a non-flat key is detected, the system activates the flipper to rotate to the second position, allowing the key to self-position correctly without manual intervention. This resolves the contradiction by maintaining ease of operation while achieving high positioning accuracy through automated self-positioning.
4Device complexity
If traditional key storage packaging is used, then simple packaging structure is achieved, but automated pick and place operations become difficult
Solution Approach 1:
Key blanks are pre-packaged in standardized containers with integrated grip features that expose the key blade. This preliminary preparation of the packaging allows the automated pick and place mechanism to easily grasp and retrieve keys without complex manipulation, resolving the contradiction between simple packaging structure and automated handling capability.
Solution Approach 2:
The packaging design incorporates universal features that work with the automated pick and place system. The standardized container with exposed blade serves multiple functions: protection, organization, and automated grasping. This multi-functionality resolves the contradiction by enabling simple yet automated key handling.
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.