Abstract:
An apparatus for positioning a key blank relative to a key cutter. The apparatus includes a frame having an axis. A carriage assembly is attached to the frame and arranged for movement in a generally axial direction and a generally transverse direction relative to the axis. A key blank holder is attached to the carriage assembly. A drive assembly coupled to the carriage assembly is selectively operable to move the carriage assembly in a generally transverse direction. A bias assembly is selectively operable to bias the carriage assembly toward the key cutter.

Description:
BACKGROUND OF INVENTION  
       [0001]     The present application relates to key cutting, and more particularly to positioning key blanks during key cutting.  
         [0002]     A key is a device, embodying a predetermined code, that functions to open a particular lock or a particular type of lock. Keys have many types, each with a particular size, shape, or modus operandi. One of the most common is a metal key, which includes a plurality of notches having predetermined depths and predetermined spacing therebetween. The spacing and depths of the notches represent the code embodied in the key.  
         [0003]     Typically, a metal key is manufactured by applying a key blank to a cutting device, such as a cutting or grinding wheel, and forming each notch according to the code. To duplicate a metal key, there are two options: First, a person privy to the key code can simply cut the pattern of notches into a key blank. This is called code cutting and is performed with a code cutting machine. Second, a person can use a key duplication machine. A key duplication machine utilizes the original key to guide the key blank relative to a cutting wheel to form notches having the same depths and spacing intervals as the notches on the original key.  
         [0004]     Code cutting machines and duplication machines often stand alone. In other words, a code cutting machine does not perform duplication, and a duplication machine does not perform code cutting. This is burdensome for locksmiths who want to provide both code cutting and key duplication services to their customers. Accordingly, what is needed is an apparatus capable of positioning a key blank relative to a cutting device in both a code cutting mode and a duplication mode.  
       SUMMARY OF INVENTION  
       [0005]     In one embodiment, an apparatus for positioning a key blank relative to a key cutter is provided. A frame having an axis has a carriage assembly attached thereto. The carriage assembly is arranged for movement in a generally axial direction and a generally transverse direction relative to the axis. A key blank holder is attached to the carriage assembly. A drive assembly is coupled to the carriage assembly for moving it in the generally transverse direction. The drive assembly has generally operable and inoperable conditions. A bias assembly also has operable and inoperable conditions. In a first operational mode, the bias assembly is inoperable, and the drive assembly is operable to impart transverse movement to the carriage assembly. In a second operational mode the bias assembly is operable to bias the carriage assembly toward the key cutter, and the drive assembly is inoperable.  
         [0006]     In one embodiment, an apparatus for positioning a key blank relative to a key cutter is provided. The apparatus includes a frame having an axis. A means is provided for connecting the key blank to the frame such that the key blank is moveable in a direction generally axial and a direction generally transverse to the axis. A means is provided for biasing the key blank toward the key cutter, the biasing means having operable and inoperable conditions. A means is provided for driving the connecting means. The driving means includes operable and inoperable conditions. In a first operational mode, the biasing means is inoperable, and the driving means is operable to impart transverse movement to the connecting means. In a second operational mode the driving means is inoperable and the biasing means biases the connecting means toward the key cutter.  
         [0007]     In one embodiment, a key cutting machine having a duplication mode and a code cutting mode is provided. The machine includes a frame, a key cutter mounted to the frame, a carriage moveably attached to the frame, and a key blank holder positioned on the carriage. A gauge is mounted to the frame that measures a location of the carriage assembly relative to the key cutter. An engagement member is moveably attached to the carriage. The engagement member is moveable between a first position, corresponding to the code cutting mode, in which it engages the gauge, and a second position, corresponding to the duplication mode, in which it is disengaged from the gauge. 
     
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0008]      FIG. 1  is a top perspective view of a key cutting machine while in code cutting mode;  
         [0009]      FIG. 2  is a top perspective view of the key cutting machine in  FIG. 1  while in duplication mode;  
         [0010]      FIG. 3  is a sectional view taken along the line  3 - 3  of  FIG. 1 ;  
         [0011]      FIG. 4  is a sectional view taken along the line  4 - 4  of  FIG. 2 ;  
         [0012]      FIG. 5  is an enlarged sectional view taken along line  5 - 5  of  FIG. 1 ; and  
         [0013]      FIG. 6  is an enlarged sectional view taken along line  6 - 6  of  FIG. 2 . 
     
    
     DETAILED DESCRIPTION  
       [0014]     Referring to  FIGS. 1 , key cutting machine  10  in one example comprises frame  20 , carriage assembly  30 , transverse drive assembly  50 , axial drive assembly  60 , display assembly  70 , cutting assembly  80  and motor assembly  90 .  
         [0015]     Frame  20  is shown in  FIG. 1  for exemplary purposes as a housing  21  having sidewalls  22 , and end walls  24 , which define an enclosure. Some components (e.g. carriage assembly  30 ) of key cutting machine  10  are shown mounted externally to housing  21 , whereas others (e.g. portions of display assembly  70 ) are internal to housing  21 . This is shown for illustrative purposes only. Alternatively, key cutting machine  10  could have another arrangement. For example, frame  20  could comprise one or more support members attached to a base with the components of key cutting machine  10  attached to the support member(s). Frame  20  can be made of any material sufficient to support the components of key cutting machine  10  such that it can operate to produce keys. Examples include, but are not limited to, metals, stainless steel, and plastics. Frame  20  includes at least one axis  25  upon which carriage assembly  30  pivots.  
         [0016]     Carriage assembly  30  is mounted to frame  20  such that it moves axially and transversely relative to axis  25 . Carriage assembly  30 , in one example, comprises first body member  32 , a second body member  34 , first shaft  36 , second shaft  38 , third shaft  40 , and slide member  42 . Carriage assembly  30  is attached to frame  20  by first shaft  36 . First shaft  36  is connected on one end to first body member  32  and is pivotally and slidably disposed on frame  20 . First body member  32  and second body member  34  are attached together by second shaft  38  and third shaft  40 . Slide member  42 , in one example, is a collar or cylindrical piece of material disposed on third shaft  40  and capable of sliding longitudinally along the length of third shaft  40 . As will be discussed further herein, slide member  42  engages with display assembly  70  to provide a user with a measure of the relative location of carriage assembly  30  with respect to cutting wheel  82  located in cutting assembly  80 . A key blank holder  44 , shown holding key blank  45 , is attached to first body member  32 , and a key holder  46  for holding a key to be copied, is attached to second body member  34 .  
         [0017]     Transverse drive assembly  50  operates to move carriage assembly  30  in a direction transverse to axis  25 . Transverse drive assembly  50 , in one example, comprises a support shaft (not shown), knob  52 , handle  54 , and lock pin  56 . The support shaft, as will be discussed further herein, is rotatably engaged with frame  20 . Knob  52  is attached to the support shaft. In code cutting mode, when knob  52  is rotated clockwise, it bears against carriage assembly  30  and moves carriage assembly  30 , in a transverse direction relative to axis  25 , toward cutting assembly  80 .  
         [0018]     Handle  54  is rotatably attached to knob  52 . A user grasps handle  54  to rotate knob  52 . Handle  54 , as will be discussed further herein, also has two positions relative to knob  52 . In one position (shown in  FIG. 1 ), handle disengages a bias assembly (not shown) and cutting machine  10  is operable for code cutting. In another position (shown in  FIG. 2 ), handle  54  activates the bias assembly. The bias assembly then forces carriage assembly  30  toward cutting assembly  80  and cutting machine  10  is operable for key duplication.  
         [0019]     Lock pin  56  is located in an opening of knob  52 . Lock pin  56  is adjustable. Lock pin  56  has a first position, shown in  FIG. 5 , in which lock pin  56  is retracted from frame  20 . This position is appropriate for code cutting. Lock pin  56  also has a second position, shown in  FIG. 6 , in which one end of lock pin  56  is engaged with frame  20  and knob  52  cannot rotate. This position is appropriate for duplication.  
         [0020]     Axial drive assembly  60  moves carriage assembly  30  in an axial direction relative to axis  25 . Axial drive assembly includes, a support shaft (not shown), knob  62 , and handle  64 . A user turns knob  62  through utilization of handle  64  to operate axial drive assembly  60 .  
         [0021]     Display assembly  70  includes a readout  72  and spring loaded plunger  78 . Readout  72 , in one example, includes space needle  73 , space indicia  74 , depth needle  75 , depth indicia  76 . Space needle  73  communicates with axial drive assembly  60 , and in conjunction with space indicia  74 , provides the axial location of key blank  45  relative to cutting assembly  80 . Depth needle  75  communicates with plunger  78 , and in conjunction with depth indicia  76 , provides the transverse location of carriage assembly  30  relative to cutting wheel  82 .  
         [0022]     Space indicia  74  and depth indicia  76  can be provided on separate code cards produced by the manufacturer key cutting machine or by some other party. The code cards provide the code for a particular key to be cut. Examples of the code cards and the mechanisms through which display assembly  70  works can be found in U.S. Pat. Nos. 4,117,763, 4,090,303, 4,012,991, and 5,054,350, which are hereby incorporated by reference.  
         [0023]     When knob  62  is turned it engages a mechanism within frame  20  that causes carriage assembly  30  to move axially. In one example, the mechanism includes a steel shaft with embedded threads connected to knob  62  that transfers motion to an aluminum casting that has a dual purpose. The first purpose of the aluminum casting is that it holds a rack that engages the spacing gear, which in turn moves the space needles  73 . The other purpose of the aluminum casting is to connect to shaft  36  via a dog point screw, which allows for free depth motion while maintaining constant pressure by utilizing a spring to force the aluminum casting to be biased in one direction to ensure accurate positioning. Shaft  36  is directly connected to carriage  30 . This mechanism can be found in the above referenced patents.  
         [0024]     Plunger  78  is mounted to frame  20  and is biased toward carriage assembly  30 . In key cutting mode, slide member  42  is positioned in engagement with plunger  78 . Plunger  78  biases carriage assembly  30  so that it remains in contact with knob  52  of transverse drive assembly  50 . When a user operates transverse drive assembly  50 , slide member  42  either depresses or withdraws pressure from plunger  78 . Plunger  78  engages a mechanism within frame  20  to move depth needle  75  along depth indicia  76 . In one example, plunger  78  is connected to a rack, which contacts a gear that is directly connected to depth needle  75 . Accordingly, depth needle  75  moves along depth indicia  76  as plunger  78  is depressed and withdrawn. This mechanism can be found in the above referenced patents.  
         [0025]     Cutting assembly  80  includes the cutting wheel  82 , which is mounted to a shaft (not shown) engaged with motor assembly  90 . Cutting wheel  82  rotates around the shaft and also pivots in the direction indicated by arrow “A” to allow a user to make angle cuts. A pivot pin  86 , connected to cutting assembly, allows a user to pivot cutting wheel  82 .  
         [0026]     Motor assembly  90  turns cutting wheel  82 . In one example, motor assembly  90  includes a 110 V motor (not shown). The motor is attached to cutting wheel through a mechanism, such as a belt and shaft assembly, which causes motor to turn cutting wheel  82 . Alternatively, other motors or other devices, such as hand cranks, could be used to turn cutting wheel. A deburring brush  92  can be attached to a shaft of motor assembly  90  which can be used to deburr a key after cutting.  
         [0027]     A description of the operation of key cutting machine  10  while in code cutting mode is provided for illustrative purpose.  
         [0028]     To code cut a key, a user inserts key blank  45  into key blank holder  44 . The user chooses the particular code card, which corresponds to the key that the user intends to cut. The user inserts the code card into readout  72 . The user must then place key cutting machine in the code cutting operational mode. Accordingly, if handle  54  on drive assembly  50  is not in the position shown in  FIG. 1 , the user places handle  54  in this position. If lock pin  56  is not in the position shown in  FIG. 1 , the user pulls lock pin  56  back to disengage it from frame  20 . The user must also position slide member  42  into engagement with plunger  78 . If slide member  42  is not in the position shown in  FIG. 1 , the user moves slide member  42  into engagement with plunger  78 .  
         [0029]     The user, by utilizing transverse drive assembly  50  and axial drive assembly  60 , then moves carriage assembly  30  such that key blank  45  is in a desired position relative to cutting wheel  82 . In the example shown, clockwise rotation of transverse drive assembly  50  causes knob  52  to bear against second shaft  38  of carriage assembly and rotate carriage assembly  30  relative to axis  22 . This causes key blank  45  to move toward cutting wheel  82 . Conversely, counterclockwise rotation of transverse drive assembly  50  removes the pressure of knob  52  bearing against shaft  38 . Plunger  78  then pushes carriage assembly  30 , and key blank  45 , away from cutting wheel  82 . Meanwhile, plunger  78  communicates with display assembly  70  to cause depth needle  75  to move relative to depth indicia  76 , and thereby provide the depth of the notch cutting wheel  82  will make in key blank  45 .  
         [0030]     Clockwise rotation of axial drive assembly  60  causes carriage assembly  30  to move axially toward knob  62 . Counterclockwise rotation causes carriage assembly  30  to move away from knob  62 . Axial drive assembly  60  communicates with display assembly  70  to move space needle  73  relative to space indicia  74  as carriage assembly  30  moves. In this manner, user has an indicator of the longitudinal location of the notch that cutting wheel  82  will make on key blank  45 . This allows the user to space the notches at appropriate distances from each other. It should be noted that the directions of rotation for both transverse drive assembly  50  and axial drive assembly  60  are provided for illustrative purposes. The directions of rotation could be reversed without departing from the scope of the application.  
         [0031]     After moving key blank  45  to a desired spacing location, the user powers motor assembly  90  to turn cutting wheel  82 , the user moves key blank  45  to the desired depth location, which then cuts a notch in key blank  45 . Alternatively, the user can turn the power on first and then move key blank  45  to the desired position to make a particular cut. As will be understood by those in the art, the user makes a series of cuts on key blank  45  by utilizing transverse drive assembly  50  and axial drive assembly  60  to position key blank  43  in a number of positions relative to cutting wheel  82 . The position of key blank relative to cutting wheel  82  is provided to the user by space needle  73 , space indicia  74 , depth needle  75 , and depth indicia  76 . In either case, the user makes the cuts on key blank  43  in accordance with the code provided on the code card.  
         [0032]     Referring to  FIG. 2 , an exemplary description of key cutting machine  10  while in duplication mode will now be provided for illustrative purposes.  
         [0033]     To duplicate a key, the user places key blank  45  in key blank holder  44  and key  201  in key holder  44 . Before duplicating the key  201 , the user must place key cutting machine in duplication mode. Accordingly, if handle  54  on drive assembly  50  is not in the position shown in  FIG. 2 , the user places handle  54  in this position. If lock pin  56  is not in the position shown in  FIG. 2 , the user pushes lock pin  56  forward to engage it with frame  20 . Similarly, the user must also position slide member  42  so that it is not engaged with plunger  78 . As will be discussed further herein, by positioning handle  54  as shown in  FIG. 2 , a pin  205  engages shaft  38  of carriage assembly  30  and biases it toward cutting wheel  82 . This forces key  201  into engagement with a key tracer  203 , which is mounted to frame  20 . By positioning lock pin  56  in engagement with frame  20 , transverse drive assembly  50  is disengaged. The disengagement of transverse drive assembly  50  prevents rotation of knob  52 , and prevents knob  52  from moving and interfering with the bias pin  205  applies to carriage assembly  30 .  
         [0034]     After engaging key  201  with key tracer  203 , the user powers motor assembly  90 . The user then rotates axial drive assembly  60  to move key blank  45  into engagement with cutting wheel  82 . As will be understood by those in the art, as carriage assembly  30  moves axially, key tracer  203  traces the notch configuration of key  201 .  
         [0035]     Carriage assembly  30  maintains key blank  45  and key  201  in a fixed position relative to each other. Accordingly, when key tracer  203  causes the carriage assembly  30  to pivot away from cutting wheel  82 , key blank  45  pivots away from cutting wheel  82 . When pin  205  causes carriage assembly  30  to pivot toward cutting wheel  82 , the key blank  45  pivots toward cutting wheel. In other words, the force of pin  205  pushing carriage assembly  30  toward key tracer  203 , and the opposing force of key tracer  203  pushing against key  201 , creates a cam-like action that causes carriage assembly  30  to move according to the spaces and depths of the cuts in key  201 . This causes cutting wheel  82  to engage key blank  45  at the same locations and depths as key  201 .  
         [0036]     Referring to  FIG. 3 , axial drive assembly  50  includes knob  52  attached to support shaft  301 . Support shaft  301  is positioned in openings  303 ,  304  formed in opposing sidewalls  305 ,  306  of frame  20 . Support shaft  301  has threads  307 , which engage threads  308  located in opening  304 .  
         [0037]     Plunger  78  is positioned in openings  310 ,  312  located in sidewalls  305 ,  306 . Plunger  78  is biased by spring  314  toward carriage assembly  30 .  
         [0038]     When key cutting machine  10  is in code cutting mode, pin  205  ( FIG. 2 ) is disengaged, allowing knob  52  to contact second shaft  38  of carriage assembly  30 . Lock pin  56  is disengaged from detent  318  located on frame  20  and therefore knob  52  can rotate. Slide member  42  is positioned to engage plunger  78 . As knob  52  is rotated, threads  307  on support shaft  301  engage threads  308 , which depending on the direction of rotation, draw knob  52  toward or away from carriage assembly  30 . If knob  52  is rotated clockwise, knob  52  engages shaft  38  and causes slide member  42  to compress spring  314  on plunger  78  and push key blank  45  toward cutting wheel  82 . As knob  52  is rotated counterclockwise, knob  52  is drawn away from shaft  38  and key blank  45  will pivot away from cutting wheel  82  due to the bias of spring  314 .  
         [0039]     Referring to  FIG. 4 , in duplication mode, pin  205  pushes against shaft  38  and carriage assembly  30  is biased toward cutting wheel  82 . In code cutting mode, pin  205  is retracted within knob  52  and does not engage carriage assembly  30  ( FIG. 3 ).  
         [0040]     Further, in duplication mode, drive assembly  50  is disengaged by placing knob  52  in the locked position. Knob  52  is locked by engaging lock pin  56  engaged with the detent  318  to prevent clockwise or counterclockwise rotation of the depth crank. Because slide member  42  does not engage with plunger  78 , plunger  78  does not bias carriage assembly away from cutting wheel  82 .  
         [0041]     Referring to  FIGS. 5 and 6 , maintaining lock pin  56  in a “locked” or “unlocked” position may be accomplished by a variety of means. In the example, shown, a ball bearing  501  is positioned in a channel  503  located in the interior of knob  52 . Ball bearing  501  is biased against the lock pin  56  by a resilient spring  505 . Lock pin  56  has first grooves  507  to engage ball bearing  501  in a locked position ( FIG. 6 ), and second groove  509  to engage ball bearing  501  in an unlocked position ( FIG. 5 ).  
         [0042]     As was stated earlier, pin  205 , in duplication mode ( FIG. 6 ) pushes against shaft  38  to bias carriage assembly toward the cutting wheel. Pin  205  is part of a bias assembly that includes handle  54 , pin  205 , and spring  520 . Handle  54 , in one example, includes gripping portion  503  and intermediate portion  521 . Handle  54  is rotatably attached to pin  205  at intermediate portion  521  by pivot pin  510 . Pin  205  is disposed in a channel  511  located in knob  52 . Spring  520  is attached to pin at one end by collar  512 . At another end spring engages sidewalls  513  of channel  511 . Spring  520  engages sidewalls  513  and biases pin  205  toward shaft  38 .  
         [0043]     Handle  54  pivots around pin  205 , so that when gripping portion  503  is extended (as shown in  FIG. 5 ), pin  205  is retained completely within channel  511 . When gripping portion  503  is folded, spring  520  pushes one end  515  of pin  205  out of channel  511 . Pin  205  thus engages shaft  38  ( FIG. 6 ).  
         [0044]     It should be noted that the particular arrangement of the bias assembly is shown for illustrative purposes only. The bias assembly could be a mechanism separate from knob  52  that engages carriage assembly  30  to push it toward cutting wheel  82  in one mode and disengages from carriage assembly in another mode. For instance, bias assembly could be a spring mounted pin mounted to another portion of frame.  
         [0045]     While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants&#39; contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.