Self-Learning Lock Cylinder With Modular Wafer Verification
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Solution Overview
Problem
Current lock cylinders and keys in automotive applications often require replacement due to wear or damage, and existing rekeying methods are complex, requiring skilled intervention and lack verification of copy key functionality.
Innovation Solution
A self-learning lock cylinder assembly that allows users without locksmith experience to reuse original keys by configuring and testing the key's functionality through a self-learning process, using wafers with compression springs and a testing housing to ensure correct assembly and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If current rekeying methods are used, then lock cylinder can be rekeyed, but it requires skilled locksmith intervention and complex disassembly/reassembly procedures
Solution Approach 1:
The lock cylinder is divided into separate modular components including a housing, plug, and multiple independent wafer elements. Each wafer can be individually replaced or reconfigured without affecting other components, allowing simple rekeying by swapping wafer sets rather than disassembling the entire lock mechanism.
Solution Approach 2:
The invention uses duplicate wafer elements (first wafer and second wafer) that can be pre-configured with identical key configurations. A master key can duplicate the coding between wafers, allowing multiple keys to be created from a single original key through a simple copying process rather than complex rekeying procedures.
2Ease of manufacture
If lock cylinder is replaced, then defective lock can be replaced, but verification of key functionality is not possible before installation
Solution Approach 1:
The lock cylinder assembly includes a test feature that allows the key configuration to be verified before final installation. The wafer elements can be preliminarily tested with the key in the housing to ensure proper alignment and functionality, and any misaligned wafers can be identified and corrected before the lock is permanently installed.
Solution Approach 2:
A test housing or intermediary testing mechanism is provided that allows the key and wafer assembly to be tested independently of the final installation location. This intermediary testing setup enables verification of key functionality without requiring installation in the actual lock body, and the same assembly can then be transferred to the final installation.
3Adaptability or versatility
If traditional rekeying procedures are used, then lock can be rekeyed, but incorrect assembly may occur without detection
Solution Approach 1:
The wafer elements include alignment features and test mechanisms that provide immediate feedback on correct assembly. When wafers are incorrectly assembled or aligned, the test feature detects this through mechanical interference or misalignment indicators, providing clear feedback to the assembler that correction is needed before final installation.
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
Enables simplified replacement of defective lock cylinders with verified functionality of original and copy keys, eliminating incorrect assembly issues and ensuring proper operation without requiring advanced technical expertise.
Implementation Method 1
The compression springs abut the limiting stops and bias the wafers against the coding surface or topography of the original key
Implementation Method 2
The compression springs abut the limiting stops and bias the wafers
Data Source
AI summary
A self-learning lock cylinder assembly or lock tumbler and tools capable of teaching the self-learning key configuration of a pre-existing key is disclosed. The individual performing the self-learning does not need to have prior locksmith experience. The individual performing the self-learning procedure can verify that the original key and copies of the original key function properly within the lock cylinder prior to final assembly and installation in the lock through a self-learning test housing. The pre-installation testing eliminates problems associated with an incorrectly assembled lock cylinder.