Key Imaging Flipper and Storage Matrix for Duplicate Key Retrieval
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Solution Overview
Problem
Key cutting machines face challenges in accurately imaging and positioning non-flat master keys, leading to errors in capturing key information, and existing systems struggle with efficient storage and retrieval of diverse key formats, resulting in incorrect selections and product waste.
Innovation Solution
A key-receiving and positioning component, such as a flipper mechanism, is used to accurately position non-flat keys for imaging, and a storage system with a pigeonhole or honeycomb matrix for automated key selection and inventory management, including a gripper mechanism for handling various key types and formats, and a collective delivery system for multiple orders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flat scanning surface is used for imaging master keys, then the imaging process is simple, but non-flat keys cannot be accurately positioned and imaged
Solution Approach 1:
The patent introduces a movable flipper mechanism that can change position between a first position (for non-flat keys) and a second position (for flat keys). This dynamic adjustment allows the system to adapt to different key types, enabling accurate imaging of non-flat keys while maintaining simplicity for flat keys.
Solution Approach 2:
The scanning surface is divided into multiple segments: a fixed flat surface and a movable flipper portion. This segmentation allows each segment to be optimized for specific key types, with the flipper segment providing angled support for non-flat keys and the flat surface handling standard flat keys.
2Adaptability or versatility
If a variety of key formats are stored, then customer service coverage is improved, but storage and retrieval complexity increases
Solution Approach 1:
The patent designs a universal key holder assembly that can accommodate multiple key formats through adjustable components. The flipper mechanism and gripper system can be configured to handle different key types (flat keys, non-flat keys, keys with heads, etc.), eliminating the need for separate storage systems for each key format.
Solution Approach 2:
The storage system uses adjustable parameters such as flipper angle, gripper position, and holder orientation to adapt to different key formats. By changing these parameters, the system can securely store and retrieve various key types without requiring complex dedicated structures for each format.
3Productivity
If automated key selection is implemented, then retrieval efficiency is improved, but system complexity and cost increase
Solution Approach 1:
The patent implements a self-service automated selection system where the processor controls the flipper mechanism and gripper to automatically position and retrieve keys based on customer selections. The system self-manages the retrieval process without requiring manual intervention, improving efficiency while keeping complexity manageable through programmable control.
Solution Approach 2:
The flipper mechanism serves as an intermediary between the key storage and the cutting mechanism. It automatically positions keys in the correct orientation and delivers them to the gripper, which then transfers them to the cutting area. This intermediary system automates the retrieval process while maintaining simplicity through mechanical coordination.
4Device complexity
If non-flat keys are imaged on a flat surface, then the imaging setup is simple, but imaging errors occur
Solution Approach 1:
The flipper mechanism dynamically adjusts from a flat position to an angled position to match the contour of non-flat keys. This dynamic adjustment ensures that the key surface is properly aligned with the imaging device, eliminating imaging errors while maintaining a simple setup that adapts to different key types.
Solution Approach 2:
The flipper is designed with an asymmetric angled surface that specifically accommodates non-flat keys with raised portions or heads. This asymmetric design allows the flipper to provide the correct angular support for non-flat keys, ensuring accurate imaging without requiring complex adjustable mechanisms.
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.