Abstract:
A clamp is disclosed for use in a key making machine. The clamp may have a stationary head guide with a slot configured to receive a key, and a pressure pad configured to engage the head guide and sandwich the key therebetween. The clamp may also have at least a first spring configured to continuously generate a force biasing the pressure pad toward the stationary head guide, a plunger configured to selectively engage the pressure pad, and a second spring configured to bias the plunger toward the pressure pad. The clamp may further have a release lever manually operable to urge the plunger away from the pressure pad and to compress the second spring.

Description:
RELATED APPLICATIONS 
       [0001]    This application is based on and claims the benefit of priority from U.S. Provisional Application No. 62/256,236 entitled MANUAL CLAMP FOR KEY MAKING MACHINE that was filed on Nov. 17, 2015, the contents of which are expressly incorporated herein by reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The present disclosure is directed to a key making machine and, more particularly, to a manual clamp for a key making machine. 
       BACKGROUND 
       [0003]    Key making machines are used to create copies of master keys. In conventional machines, a master key is mounted into a clamp and held stationary while an image of the master key is captured. The image is then used to reproduce a corresponding pattern of notches within a key blank, thereby replicating the master key. 
         [0004]    An exemplary key making machine is disclosed in U.S. Patent Application Publication 2012/0243957 of Drake et al. that published on Sep. 27, 2012 (“the &#39;957 publication”). In particular, the &#39;957 publication discloses a machine that uses an optical imaging device to capture a silhouette of an inserted master key. The silhouette is measured to determine a depth, angle, and position of each tooth in the master key, and to determine if the master key includes a pattern on one side or on both sides. In order to capture the silhouette, the master key is manually secured inside the machine. Specifically, a user of the machine manually grasps a handle of a door clamp, and lifts upward to raise the door clamp against a spring bias. The master key is then placed within a slot formed in a base, and the door clamp is lowered back down onto the master key by the user. The spring bias causes the door clamp to maintain a downward force against the master key during imaging. 
         [0005]    Although the key making machine of the &#39;957 publication may be adequate for some applications, it may still be less than optimal. In particular, it may be difficult for the door clamp to exert enough force on the master key to keep it secure during imaging, without making raising of the door clamp overly difficult for some users. In addition, it may be possible for the master key to be misaligned and/or to be mishandled during manual insertion while the door clamp is raised. 
         [0006]    The disclosed clamp and key making machine are directed to overcoming one or more of the problems set forth above and/or other problems of the prior art. 
       SUMMARY 
       [0007]    In one aspect, the present disclosure is directed to a clamp for a key making machine. The clamp may include a stationary head guide having a slot configured to receive a key, and a pressure pad configured to engage the stationary head guide and sandwich the key therebetween. The clamp may also include at least a first spring configured to continuously generate a force biasing the pressure pad toward the stationary head guide, a plunger configured to selectively engage the pressure pad, and a second spring configured to bias the plunger toward the pressure pad. The clamp may further include a release lever manually operable to urge the plunger away from the pressure pad and to compress the second spring. 
         [0008]    In another aspect, the present disclosure is directed to a key making machine. The key making machine may include a housing having an opening configured to receive a key, an imaging system located within the housing and configured to capture an edge profile of the key, and a cutting system located within the housing and configured to cut a biting pattern into the key. The key making machine may also include a clamp configured to secure the key during at least one of an imaging process and a cutting process. The clamp may have a stationary head guide with a slot configured to receive a key, and a pressure pad configured to engage the stationary head guide and sandwich the key therebetween. The clamp may also have at least a first spring configured to continuously generate a force biasing the pressure pad toward the stationary head guide, a plunger configured to selectively engage the pressure pad, and a second spring configured to bias the plunger toward the pressure pad. The clamp may further have a release lever manually operable to urge the plunger away from the pressure pad and to compress the second spring. 
         [0009]    In another aspect, the present disclosure is directed to a method of clamping a key within a machine. The method may include pressing a lever to reduce a spring bias urging a pressure pad toward a head guide. The method may also include inserting a key between the pressure pad and the head guide, causing the pressure pad to move away from the head guide against a spring bias. The method may further include releasing the lever to increase the spring bias clamping the key between the pressure pad and the head guide during at least one of an imaging process and a cutting process performed on the key. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a cutaway view illustration of an exemplary disclosed key making machine; 
           [0011]      FIG. 2  is an isometric view illustration of an exemplary disclosed clamp that may form a portion of the key making machine of  FIG. 1 ; 
           [0012]      FIG. 3  is a top plan view of the clamp of  FIG. 2 ; 
           [0013]      FIG. 4  is a perspective illustration of the key making machine and clamp of  FIGS. 1-3 , from an internal perspective; and 
           [0014]      FIGS. 5 and 6  are cross-sectional side views of the clamp of  FIGS. 2 and 3  shown in two different operating positions. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]      FIG. 1  illustrates an exemplary key making machine (“machine”)  10  that can be used to fabricate a copy of an existing master key from a corresponding key blank. For example, machine  10  may be used to capture an edge profile of the master key and/or to create within the key blank a biting pattern corresponding to the edge profile. In the disclosed embodiment, machine  10  includes an imaging system  12  configured to generate the edge profile of the master key, and a clamp  16  configured to secure the master key during profile generation. Imaging system  12  and clamp  16  may be co-located within a common housing  18 , portions of which have been removed from  FIG. 1  for clarity. It is contemplated that machine  10  could include additional or alternative systems (e.g., a cutting system, an inventory system, a debris removal system, etc.), if desired. For example, clamp  16  could additionally or alternatively be used to secure the key blank during biting profile generation by the cutting system. For the purposes of this disclosure, the term “key” will be used throughout the remainder of this disclosure to generically represent the master key and/or the key blank. 
         [0016]    An exemplary embodiment of clamp  16  is shown in  FIGS. 2-4 . As is shown in these figures, an opening  20  may be formed in a front panel of housing  18  to provide user-access to clamp  16 ; a fixed head guide  22  having an internal slot  23  may be positioned at opening  20 ; and a movable tip guide  24  may be positioned behind head guide  22 . Each of these components may cooperate to receive the key as it is inserted by the user shank-first through opening  20 . Edges  25  of slot  23  may be beveled inward toward a general center such that, as the key is inserted, the head of the key may engage the bevels and be urged toward the center (i.e., toward greater alignment with tip guide  24 ). The key may be inserted until the head engages lateral sides of head guide  22  to about the same degree. In most applications, this engagement should result in the key being lengthwise aligned with tip guide  24  (e.g., within a desired angle). Tip guide  24  may slide from opening  20  inward to a desired imaging/cutting position during and/or after insertion of the key into head guide  22 . In some embodiments, a sensor  27  (e.g., an optical sensor—shown only in  FIG. 2 ) may be used to detect movement of tip guide  24  and thereby trigger activation of machine  10 . For example, sensor  27  may be configured to generate a beam of energy that passes through a corresponding gap  29  in tip guide  24  at a time when tip guide  24  is situated to receive the key. As tip guide  24  is pushed inward during key insertion, gap  29  may move past sensor  27  such that the beam of energy is blocked by tip guide  24 . The blocking of the beam may result in a signal being generated that is indicative of key insertion. 
         [0017]    As the key is being loaded into head guide  22  (and into tip guide  24 ), the key may need to be secured to reduce misalignment and mishandling errors. For this reason, clamp  16  may further include a movable pressure pad  26  that is biased downward (relative to the perspective shown in  FIGS. 2 and 4 ) against head guide  22  by a pair of springs  28  located at opposing ends of pressure pad  26  (i.e., at opposing sides of slot  23 ). Each spring  28  may internally receive a vertical guide rail  30  that passes through both of head guide  22  and pressure pad  26 , and be held in place via a snap ring  32  connected to a distal end of guide rail  30 . With this configuration, the head of the key may be sandwiched between a lower surface of pressure pad  26  and an upper surface of slot  23 . In one embodiment, springs  28  may together apply a continuous downward force of about 3 lbs. on the head of the key. As the user pushes the key into head guide  22 , pressure pad  26  may be urged by the engagement with the key upward against the bias of springs  28  and away from head guide  22 . In some embodiments, one or more travel limiters  31  may be used to limit a maximum distance that pressure pad  26  may be moved away from head guide  22  during insertion of the key. It is contemplated that travel limiters  31  may be omitted, if desired, and/or that another configuration of springs  28  may alternatively be implemented to provide the continuous downward bias on pressure pad  26 . 
         [0018]    While the continuous bias of springs  28  exerted on pressure pad  26  against the head of the key may help to reduce misalignment and mishandling errors during loading, the bias may be insufficient for subsequent imaging and/or cutting processes. That is, the key may need to remain completely stationary during the subsequent process(es), and an additional temporary biasing force may be used for this purpose after the key is already located between head guide  22  and pressure pad  26 . The temporary biasing force may be provided via an additional spring  33 , and exerted on pressure pad  26  via a plunger  34 . In particular, as shown in  FIG. 4 , plunger  34  may be reciprocally disposed to slide within a vertical bore  36  of a block  38  that is mounted gravitationally above pressure pad  26 , and spring  33  may be compressed between a bottom surface of block  38  and a snap ring  39  that is connected to a midpoint of plunger  34 . In this location, spring  33  may generate a force on plunger  34 , urging plunger  34  downward against the upper surface of pressure pad  26 . In the disclosed embodiment, the additional force generated by spring  33  may be about 12 lbs., making for a total of about 15 lbs. pressing down on the head of the key. 
         [0019]    The combined forces of springs  28  and spring  33  pressing down on the key may be too large in some instances for the user to overcome simply by pushing the key into slot  23 . In these instances, a mechanical advantage may be provided to help reduce the effort required from the operator. In the disclosed embodiment, the mechanical advantage is provided by way of a lever arm. Specifically, a release lever  40  may be pivotally connected at an internal end to plunger  34  via a first pivot pin  42 . For example, pivot pin  42  may pass transversely through plunger  34 , and release lever  40  may be forked at its internal end to receive pivot pin  42  between corresponding tines  41 . Release lever  40  may also be pivotally connected to block  38  via a second pivot pin  44  that passes transversely though a shaft of release lever  40 . A push button or handle  46  may be formed at an external end of the release lever shaft. In this configuration, second pivot pin  44  may function as a fulcrum, such that, when handle  46  is pushed downward by the user, plunger  34  may be pulled upwards and away from pressure pad  26  with a mechanically multiplied moment. When this occurs, the force urging pressure pad  26  toward head guide  22  may be reduced (e.g., from about 15 lbs. to about 3 lbs.). In some embodiments, a travel limit pin  48  may protrude inward from plunger  34  and pass into a window  50  formed within an inward face of block  38 . The engagement of pin  48  with upper and/or lower ends of window  50  may limit a travel of plunger  34  that can be caused by the movement of release lever  40 . 
         [0020]    In some embodiments, a micro-switch  52  may be mounted at an upper end of plunger  34 . As plunger  34  is pulled upward by the downward pressing of release lever  40 , the upper end of plunger  34  may engage micro-switch  52 . This engagement may trigger micro-switch  52  to generate a corresponding signal. Additionally or alternatively, as plunger  34  is allowed to move back downward by the release of lever  40 , the upper end of plunger  34  may move away from micro-switch  52  and generate another corresponding signal. The signal(s) generated by micro-switch  52  may be used to initiate, adjust, and/or terminate an imaging process, a cutting process, and/or another key-making related process. 
         [0021]    It is contemplated that the engagement of plunger  34  with micro-switch  52  may be adjustable, if desired. For example, an adjusting screw/nut combination  54  may be located at the upper end of plunger  34 . With this configuration, a relative turn of combination  54  may affect a distance that plunger  34  protrudes towards micro-switch  52 . Other adjustment mechanisms may additionally or alternatively be included. 
         [0022]      FIGS. 5 and 6  illustrate an exemplary method of clamping the key into machine  10  in preparation for an imaging process or a cutting process.  FIGS. 5 and 6  will be discussed in greater detail in the following section to further illustrate the disclosed concepts. 
       INDUSTRIAL APPLICABILITY 
       [0023]    The disclosed key making machine may be utilized to duplicate a master key from a key blank. The disclosed key making machine may be easy to use and produce a reduced number of mis-cuts due to the security provided by the disclosed clamp. An exemplary operation of the disclosed key making machine will now be described with reference to  FIGS. 5 and 6 . 
         [0024]    As shown in  FIG. 5 , to begin the duplication process, a user (e.g., a customer or sales associate) may insert the master key to be duplicated through slot  23  of head guide  22 . In order to reduce the force required to push the master key into slot  23 , the user may simultaneously push down on handle  46 , causing plunger  34  to lift upward against the bias of spring  33  and away from pressure pad  26 . This may reduce the force that must be overcome by the user during key insertion to about 3 lbs. As the key is inserted through slot  23 , pressure pad  26  may be urged upward against the bias of springs  28 . 
         [0025]    In some embodiments, the action of pushing down on handle  46  (or the corresponding lifting action of plunger  34 ) may wake (i.e., trigger activation of) the associated machine  10 . In particular, as the upper end of plunger  34  engages micro-switch  52 , micro-switch  52  may generate a corresponding signal causing machine to initiate an associated process (e.g., the imaging or cutting process). In other embodiments, the action of pushing the key through slot  23  (e.g., and moving tip guide  24  relative to sensor  27 ) may wake the associated machine  10 . In yet other embodiments, a combination of signals generated by micro-switch  52  and sensor  27  may function to wake machine  10 . 
         [0026]    After the key has been fully inserted into machine  10  (i.e., after the head of the key has engaged the beveled surfaces at slot  23  and/or after the tip end of the key shank has engaged and pushed back tip guide  24 ), the user may release handle  46  as shown in  FIG. 6 . As handle  46  is released, plunger  34  may be urged back downward and against the upper surface of pressure pad  26 . This engagement may allow spring  33  to add about 12 lbs. to the force already being exerted by springs  28  on the head of the key, and result in security of the key sufficient for the imaging and/or cutting processes to commence. It is contemplated that the downward movement of plunger  34  may cause disengagement from micro-switch  52  and that micro-switch  52  may generate a corresponding signal used to additionally or alternatively control one or more automated processes. 
         [0027]    After the shank of a master key is inserted into machine  10 , imaging system  12  (referring to  FIG. 1 ) may be triggered to capture one or more images of the shank. The images may show, among other things, an edge profile of the shank. After the shank of a key blank is inserted into machine  10  or another machine, an associated cutting system may be triggered to cut a biting pattern into the shank that matches the edge profile of the master key. 
         [0028]    To remove the key from clamp  16  (e.g., after the imaging and/or cutting process is complete), the user may again press down on handle  46  to reduce the forces holding the key secure inside slot  23 . This may reduce the clamping forces from about 15 lbs. to about 3 lbs. Thereafter, the user may pull the key out of slot  23  with little effort, and then release handle  46 . 
         [0029]    In some embodiments, tip guide  24  may be spring-biased toward slot  23 , to facilitate retrieval of the key by the user at the end of an associated process. In particular, tip guide  24  may actually push the key back through slot  23  when the clamping forces have been reduced in the manner described above. In these configurations, in order to inhibit tip guide  24  from completely ejecting the key out of machine  10  (e.g., to keep the key from falling to the floor when not properly grasped by the user), a dashpot  56  (shown only in  FIG. 1 ) may be used to dampen the returning motion of tip guide  24 . 
         [0030]    It will be apparent to those skilled in the art that various modifications and variations can be made to the disclosed clamp and key making machine. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed clamp and key making machine. It is intended that the specification and examples be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.