Patent Publication Number: US-8979446-B2

Title: Fully automatic self-service key duplicating kiosk

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Application Ser. No. 61/351,046 filed Jun. 3, 2010. 
    
    
     FIELD OF THE INVENTION 
     The invention is directed to the field of key duplication. More specifically, the invention is directed to a kiosk for automatic key duplication involving no trained human operator. It only requires a customer. 
     BACKGROUND OF THE INVENTION 
     Duplicate keys are typically cut from pre-existing master keys using a hand-operated table-top tool having two clamps, a cutting wheel, a follower and a cleaning wheel. There is a long-felt need for a fully automatic key identifying and/or duplicating machine that can provide a duplicate key for an ordinary consumer in a manner as easy as purchasing an item from a vending machine or receiving money from an automated teller machine. 
     SUMMARY OF THE INVENTION 
     In accordance with one embodiment, a self-service, fully-automatic kiosk for duplicating keys includes a kiosk housing having a customer interface for receiving payment from a customer for the purchase of at least one duplicate of the customer&#39;s key. A key-receiving entry in the housing receives at least a portion of the customer&#39;s key to be duplicated, and a key analysis system within the housing analyzes the blade of a key inserted in the key-receiving entry to determine whether the inserted key matches one of a group of preselected key types and, if so, which preselected key type is matched. A key blank magazine within the housing stores key blanks for each of the preselected key types. A key blank extraction system extracts from the magazine a key blank for the preselected key type matched by the blade of the key inserted in the key-receiving entry. Then a key duplicating system within the kiosk replicates the tooth pattern of the blade of the key inserted in the key-receiving entry, on the blade of the extracted key blank. A key-removal exit in the housing provides customer access to the key with the replicated tooth pattern for removal from the kiosk. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood from the following description of preferred embodiments together with reference to the accompanying drawings, in which: 
         FIG. 1  is a front perspective of a key-duplicating kiosk. 
         FIG. 2  is a front perspective of the same kiosk shown in  FIG. 1  with the front panel opened to reveal the internal structure. 
         FIG. 3  is a functional block diagram of the electrical system in the kiosk of  FIGS. 1 and 2 . 
         FIG. 4  is an enlarged perspective of the key entry in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 5  is a screen shot of a “Welcome” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 6  is a screen shot of a “Select A Key Design” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 7  is a screen shot of a “Select Key Quantity” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 8  is a screen shot of a “Review Order and Pay” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 9  is a screen shot of a “Insert Your Key Below” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 10  is a screen shot of an “Insert and Hold Your Key” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 11  is a screen shot of a “Please Wait . . . In Progress” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 12  is a screen shot of a “Thank You” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 13  is a screen shot of an “Email Receipt” screen in the display in the front wall of the kiosk of  FIGS. 1 and 2 . 
         FIG. 14  is a perspective view of the key entry door mechanism shown in  FIGS. 1 and 2 , with the door in its closed and latched position. 
         FIG. 15  is a front elevation of the key entry door mechanism shown in  FIG. 14 , with the door in a partially open and unlatched position. 
         FIG. 16  is front elevation of the key entry door mechanism shown in  FIG. 14 , with the door in a fully open and unlatched position. 
         FIG. 17  is a perspective view of the master key-alignment, clamping and analysis systems in the kiosk of  FIGS. 1 and 2 , with a master key fully inserted. 
         FIG. 18  is a slightly rotated and enlarged perspective view of the master-key clamping and analysis systems shown in  FIG. 17 , with the master key not yet inserted. 
         FIG. 19  is a further enlarged perspective of the master-key length sensing system in the master-key analysis system shown in  FIGS. 17 and 18 , with the tip of the master key engaging the length-sensing system. 
         FIG. 20  is an enlarged perspective view of the left-hand portion of the systems shown in  FIG. 17 , with the master key-alignment system in its fully advanced position and the profile-matching gauges in their key-engaging positions. 
         FIG. 21  is an enlarged and exploded perspective of the left-hand portion of the master-key alignment system shown in  FIGS. 17 and 20 . 
         FIG. 22  is an enlarged top plan view of the master-key alignment mechanism advanced to its intermediate or “low-force” position and with the master key not yet inserted. 
         FIG. 23  is the same top plan view shown in  FIG. 22  with the master key inserted but not fully aligned. 
         FIG. 24  is the same top plan view shown in  FIG. 23  with the alignment mechanism advanced to its most advanced or “high-force” position to fully align the master key. 
         FIG. 25  is an enlarged perspective view of the right-hand end of the master-key alignment mechanism shown in  FIG. 24 . 
         FIG. 26  is a further enlarged side elevation of a master key and one of the pins in the alignment mechanism shown in  FIG. 25 . 
         FIG. 27  is an enlarged, exploded perspective of the master key shoulder-sensing arrangement in the master-key alignment system shown in  FIGS. 21-26 . 
         FIG. 28  is an enlarged perspective view of the master key clamping assembly, with a master key fully inserted into the open clamping assembly. 
         FIG. 29  is a perspective view of the master key-alignment mechanism in its retracted position and with the profile-matching gauges engaging a fully inserted master key. 
         FIG. 30  is a further enlarged side elevation of the profile-matching gauges shown in  FIG. 29  with the profile-matching gauges disengaged from the master key. 
         FIG. 31  is a front perspective view of the key-blank magazine and the key-entry door mechanisms in the kiosk of  FIGS. 1 and 2 . 
         FIG. 32  is an enlarged front perspective view of the top of the key-blank magazine. 
         FIG. 33  is a perspective view of a stack of key blanks and a tool for loading the stack of key blanks into the key blank magazine. 
         FIG. 34  is the same perspective view shown in  FIG. 33 , with the stack of key blanks engaged by the tool. 
         FIG. 35  is a sectional view of a stack of key blanks contained in an opened box, with the tool shown in  FIGS. 33 and 34  positioned adjacent the open end of the box. 
         FIG. 36  is the same sectional view shown in  FIG. 35 , with the tool engaging the stack of key blanks in the box. 
         FIG. 37  is the same sectional view shown in  FIGS. 35 and 36 , with the stack of key blanks removed from the box by the tool. 
         FIG. 38  is the same sectional view of the tool and the stack of key blanks shown in  FIG. 37 , but positioned adjacent the upper end of the key blank magazine. 
         FIG. 39  is an enlarged front perspective view of the bottom portion of the key-blank magazine, along with the key-blank clamping assembly and carrier, in the kiosk of  FIGS. 1 and 2 , with a single key blank being extracted from the magazine. 
         FIG. 40  is the same perspective view shown in  FIG. 39  but with two stacks of key blanks in the magazine and showing the duplicate key discharge chute. 
         FIG. 41  is a front perspective view of the key-blank magazine and its transport mechanism, the key-blank clamping mechanism and carrier, the master-key clamping assembly and the cutting wheel and associated vacuum housing. 
         FIG. 42  is a top rear perspective view of the same mechanisms shown in  FIG. 41 . 
         FIG. 43  is an enlarged perspective view of the mechanism for extracting a key blank from the key-blank magazine, with an extracted key blank about to engage the alignment and clamping mechanisms. 
         FIG. 44  is the same perspective view shown in  FIG. 43  with the key-blank extraction mechanism engaging the extracted key blank and advancing that blank into the alignment and clamping mechanisms. 
         FIG. 45  is an enlarged perspective view of the key-blank clamping assembly with the extracted key blank fully inserted and the clamping mechanism still open. 
         FIG. 46  is the same perspective view shown in  FIG. 45  with the clamping mechanism closed to clamp the extracted key blank. 
         FIG. 47  is an enlarged perspective view of the key-blank clamping assembly clamping an extracted key blank, the base on which the clamping assembly is mounted, the carrier on which the base is mounted, and the cam mechanism for pivoting the base. 
         FIGS. 48 through 55 , including their respectively attendant  FIGS. 48A ,  49 A,  50 A,  51 A,  52 A,  53 A,  54 A and  55 A, are perspective views of the key-duplicating mechanisms in successive stages of a duplicating operation, with a reduced end elevation showing the angular position of the key-blank clamping assembly and its base in each stage. 
         FIG. 56  is an enlarged top front perspective of a master key and a key blank in their respective clamping assemblies during a key-duplicating operation. 
         FIG. 57  is an enlarged perspective view from the front of the left-hand side of the key-blank clamping assembly, base, carrier and transport mechanism. 
         FIG. 58  is a diagrammatic plan view of a master key clamped for engagement by a follower and a key blank clamped to be cut to reproduce the tooth profile of the master key. 
         FIG. 59  is the same diagrammatic plan view as  FIG. 58  with the follower moved about halfway along the teeth of the master key, and with the teeth already passed by the follower cut in the key blank. 
         FIG. 60  is a perspective view of a vacuum system associated with the cutting and de-burring wheels in the key duplicating system. 
         FIG. 61  is a functional block diagram of a kiosk network that includes a plurality of the kiosks of  FIGS. 1 and 2  and an associated communication system connecting all the kiosks via the internet with a central office, a payment processor and an email server. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Although the invention will be described in connection with certain preferred embodiments, it will be understood that the invention is not limited to those particular embodiments. On the contrary, the invention is intended to cover all alternatives, modifications, and equivalent arrangements as may be included within the spirit and scope of the invention as defined by the appended claims. 
     Key duplication requires analysis of the master key to determine the model and tooth pattern of the master key, and then reproducing that tooth pattern on a key blank of the same model as the master key. It is generally necessary to have the master key stationary and to firmly hold the key blank while reproducing the tooth pattern. 
     The exemplary key-duplicating kiosk shown in  FIGS. 1 and 2  has a housing  10  that includes a touch-screen display  11 , a payment device  12  such as a credit or debit card reader, a viewing window  13 , a key-receiving entry  14  that includes a door  100  that opens to reveal a key insertion slot  104 , a duplicate key discharge tray  15  and a keychain discharge tray  16 . This kiosk enables a consumer to insert a master key into the slot  104  and have the master key automatically duplicated while the head of the key is always projecting from the kiosk, just as when a key is used in a door. At the base of the viewing window  13 , three indicators lights  18   a - 18   c  are illuminated to inform the customer when to “Insert Key” (light  18   a ), “Key Accepted” (light  18   b ) or “Remove Key” (light  18   c ). The kiosk also includes a pair of speakers  19   a  and  19   b  and illuminated signs  20   a  and  20   b  to help attract customers to the kiosk. The interior of the kiosk is illuminated to facilitate viewing of the key duplicating operations through the viewing window  13 . 
     The depth and width of the kiosk housing  10  are 25″ and 34″, respectively, so that the kiosk footprint is less than about 6 square feet, to minimize the floor space occupied by the kiosk in a retail store. This kiosk has the capacity of storing more than 3000 key blanks of different types and styles. For security and safety reasons, the kiosk is entirely self-contained except for an electrical power connection. Electronic communications with the processor inside the kiosk are preferably wireless. A locked door in the front of the housing  10  permits access by only authorized personnel for replenishing the supply of key blanks inside the kiosk, or for repair or maintenance purposes. Different access privileges may be provided for merchandisers (replenishment), maintenance, and removal of cash. 
     The touch-screen display  11  contains soft touch keys denoted by graphics on the underlying display and used to operate the kiosk  10 . The touch screen preferably extends over the entire display  11  to allow customers to make displayed selections by touching the touch screen at appropriate touch keys. The display itself may take the form of a high resolution LCD, a plasma display, an LED or OLED display, a non-touch screen with selection buttons along the side, or any other type of display suitable for use in the kiosk  10 . 
     The payment device  12  may include a bill acceptor for receiving paper currency, a coin acceptor, a change dispenser, a card reader, and/or a reader or sensor for other tangible portable credit storage devices that may also authorize access to and debit a central account, such as a cellular payment system which operates via text messages from customers&#39; cell phones. 
     Turning now to  FIG. 3 , the various components of the kiosk  10  are controlled by a general-purpose processor  24  (also referred to as a PC, central processing unit (CPU) or processor such as a microcontroller or microprocessor) contained within an electrical enclosure  10   a  inside the kiosk housing  10 . It will be appreciated that the processor  24  may include one or more microprocessors, including but not limited to a master processor, a slave processor, and a secondary or parallel processor. The processor  24  communicates directly with a custom controller board  25  within the kiosk, as well as the payment device  12  and the touch screen display  11 , and executes one or more programs stored in a computer readable storage medium or memory  24   a  to control the display  11 , various mechanisms within the kiosk, and a communications interface  24   b  for communicating with remote servers and other devices. The system memory  24   a  may comprise a volatile memory (e.g., a random-access memory (RAM)) and a non-volatile memory (e.g., an EEPROM), and may include multiple RAM and multiple program memories. The payment device  12  signals the processor  24  when money and/or credits have been input via the payment device. 
     The processor  24  may include any combination of hardware, software, and/or firmware that may control the transfer of data between the kiosk and a bus, another computer, processor, or device and/or a service and/or a network. The communications interface  24   b  preferably couples the kiosk wirelessly to an external network, which is described in more detail below. The controller  25  receives signals from various sensors  29  within the kiosk, as described in more detail below, and generates control signals for solenoids  26 , relays  27  and motors  28  within the kiosk, as also described below. 
     The key-receiving entry  14  is located in a central recess  17   a  of a guard  17  that protrudes from the front of the kiosk to protect the head of a key inserted in the kiosk from being bumped. The key entry area is the same height as a door lock, making the key insertion process easy and intuitive for a customer. When the customer inserts a key into the slot  104 , only the blade portion of the key extends inside the kiosk, because the slot  104  is dimensioned to block the head portion of the key from entering the kiosk. This prevents the loss of a customer&#39;s key inside the kiosk, and also makes the customer comfortable because the head of the key is always visible to the customer while it is being analyzed and duplicated. Additionally, blocking the entry of the key head prevents the customer from inconveniently being forced to take the key off a keychain or remove identifiers from the key head to insert the key for analysis and duplication. As shown in  FIG. 4 , the base of the recess  17   a  includes graphics to help ensure that the customer inserts the key in the proper orientation for the receiving sensors and mechanism inside the kiosk, e.g., with the teeth on the key blade facing to the left. These graphics can be illuminated continuously or intermittently to attract the customer&#39;s attention, and may also be reinforced by audio instructions to the customer via the speakers  19   a ,  19   b  and video or graphic instructions via the display  11 . 
     The mechanisms inside the kiosk cabinet  10  include the following mechanisms:
         a key blank magazine for storing key blanks of different types (e.g., Schlage, Kwikset, Weiser, etc.) and different styles (plain brass, colored flag pattern, colored flower pattern, etc.),   a vandal-proof door opening, closing and latching mechanism for the key-entry door,   devices for aligning an inserted master key clamping mechanism that holds the master key in a fixed, predetermined position while that key is being analyzed and duplicated,   a key identification system that identifies the type of key blank needed to duplicate the master key on,   a follower base for holding the key blank,   a key blank extractor mechanism for loading and aligning the desired type and style of key blank from the key blank magazine into the blank clamp base,   a key cutting mechanism for cutting the blade of the selected key blank to reproduce the tooth pattern of the master key,   a de-burring mechanism for removing debris from the freshly cut duplicate key, and   a vacuum system for managing the debris from the cutting and de-burring operations.       

     The processor  24  and the custom controller board  25  are programmed to carry out the following functions:
         the processor controls audio outputs and the screens displayed to customers in response to actions taken by the customer and in response to signals produced by various sensors within the kiosk,   the controller board controls the mechanisms within the kiosk in response to actions taken by the customer and in response to signals produced by various sensors within the kiosk,   the processor collects and accumulates data regarding use of the kiosk, such as the number of duplicate keys made, the number of different types of key blanks remaining in the key-blank magazine in the kiosk, revenue generated by the kiosk by time and date, cumulative use time of parts that wear, etc., and errors that occur, and   the processor communicates via the cell modem or other network connection method with one or more remote computers/servers to transmit reports, maintenance alarms, etc. to the remote computers/servers.       

     When the kiosk is not in use by a customer, the display  11  displays a promotion, such as “Buy 2, Get 1 Free”, and a message that invites a customer to “Touch Here to Begin.” The screen may also include advertising for a third party, which can be remotely managed and automatically adapted to the kiosk venue, time of day, individual customers and other factors. When a customer stands in front of the kiosk, a proximity detector (not shown) located on the front panel of the kiosk triggers the initiation of a voiceover or video demonstration on how to use the machine. When the customer touches the touch screen  11 , the display changes to a welcome screen, shown in  FIG. 5 , that gives the customer an option to “Start Your Order Now” or select a “Help” or “Español” button. Selecting the “Help” button at any time displays an FAQ screen from which the customer can select a topic to obtain more information. Selecting the “Español” button displays the instructions in Spanish. The display may also give the customer multiple language options to choose from. Selection of the “Start Your Order Now” option changes the display to ask the customer to “Select a Key Design,” as shown in  FIG. 6 . If the customer has difficulty reaching the options on the touch screen  11 , touching a blue handicap icon at the bottom right corner of the screen changes the display to a screen that adds a numerical panel at the bottom of the screen and numbers the design choices, which facilitates selecting a key design from a wheelchair, for example. The heights of the blue handicap icon and the top of the numerical panel are preferably no more than 54 inches above the floor in front of the kiosk, to meet the requirements of ADA regulations in the U.S. 
     The screen in  FIG. 6  also includes a “Key Chain Only” option which, when touched, changes the display to a screen where the customer can select a particular style of keychain. Upon selection of a key style on the touch-screen display of  FIG. 6 , the display changes to the screen shown in  FIG. 7 , which asks the customer to select the number of keys to be purchased. This display also offers an option to “Start Over” to make any necessary changes. Promotions on keys, such as “Buy 2, Get 1 Free” or “Add Another Key at a Special Price” can also be made available to the customer on this screen, and the customer can select “Yes” or “No” to accept or reject the promotion, enter a code provided for a promotion, or swipe a retail membership or value card. 
     When the desired quantity of duplicated keys has been selected, the display changes to the “Review Order and Pay” screen shown in  FIG. 8 , which gives the customer the option of selecting “Back” to make changes to the order, to go to “Help,” to view the “Terms and Conditions” of the purchase, or to “Cancel Order.” This screen also directs the customer to swipe a credit card through the card reader slot and illustrates how to insert the card and the types of credit cards that can be used. When a credit card is swiped through the card reader  12 , the data from the credit card is automatically sent to the cell modem or other network connection for transmission to a remote server of a credit card provider for authorization of the given credit card, along with the amount of the customer&#39;s order plus a preselected additional amount to cover any additional options to be offered the customer, as discussed below, or a flat predetermined amount for any transaction by any customer. The remote credit card provider promptly returns a “yes” or “no” for the dollar amount of the customer&#39;s order to be charged to the swiped credit card. 
     If the response from the credit provider is a “no” (the selected credit card is not authorized for payment), the display may change to inform the customer that credit has been denied, inviting the customer to insert a different credit card. If no action is taken by the customer within a preselected time interval, the display asks “do you need more time,” and if no action is taken, then the display is returned to the “Touch to Start” screen. 
     If the response from the credit provider is a “yes” (the card is authorized for payment), or if the card is accepted because of a lack of connectivity with the credit provider, the system is ready to accept a key from the customer, and the door  100  is opened to permit insertion of the customer&#39;s key into a slot  104 . This authorizes the charge, but the payment will only be completed at the end of the key duplication process. At the same time the door  100  is opened, the display is changed to request the customer to insert the key to be duplicated, with instructions specifying which direction the key should be facing, as shown in the screen shot in  FIG. 9 . This screen also has an “I can&#39;t insert my key” option, which, when touched, displays a screen that informs the customer that “Your key cannot be duplicated”  FIG. 10  is a screen shot of a display that is generated if a problem is encountered during automatic alignment of the customer&#39;s key after it is inserted, as described in detail below.  FIG. 11  is a screen shot of a display generated while the customer&#39;s key is being duplicated. 
     At the end of the key duplication process the display is changed to show the customer an on-screen copy of his or her transaction receipt, as shown in  FIG. 12 . The interface has “Email Receipt” and “Start Over” buttons. The “Start Over” button ends the customer order session and restarts a new order. The “Email Receipt” button links the customer to a screen with a QWERTY style virtual keyboard, as shown in  FIG. 13 , that allows the customer to enter an email address in a field within a preselected time-out interval. Once a customer completes entering an email address into this field and touches the “Continue” button, the display changes to a screen that informs the customer that a receipt has been sent to the email address that was entered. When the transaction is complete, the display gives the customer an option to send a text or email message with a coupon code inviting another person to use the machine. The display also allows the customer to send a message from the machine to a group of people on a social network. Furthermore, the display gives high volume customers the option of enrolling in a frequent buyer program which sends the customers special promotions or discounts for future purchases. 
       FIGS. 14-16  illustrate an automated key-entry door mechanism that includes a latch to hold the door  100  in its closed position until the customer is instructed to insert a key to be duplicated. The door  100  is formed by a horizontally elongated plate that slides between outer and inner stationary plates  101  and  102  having registered key-entry apertures  103  and  104 . The aperture  104  in the inner stationary plate  104  is in the form of a horizontal key-entry slot, so that it permits the key blade to enter the kiosk but blocks entry of the head of the key. The movable plate  100  also has a key-entry aperture  105  that is slightly smaller than the aperture  102  in the outer stationary plate  101 , but only when the movable plate  100  is in its open position, illustrated in  FIG. 16 . When the movable plate  100  is in its closed position, as illustrated in  FIG. 14 , a solid portion of the plate  100  covers the apertures in the two stationary plates  101  and  102 . 
     To latch the movable plate  100  in its closed position, so that the closure of the key-receiving entry is tamper-proof, a first latch element  110  is pivotably coupled to one end of the plate  100 . This first latch element  110  includes a hooked portion  110   a  that meshes with a second latch element  112  having a hooked portion  112   a  and pivotably coupled to a stationary pin  113 . The first latch element  110  is urged toward the second latch element  112  by a coil spring  114  that has one end attached to the first latch element  110 , and a second end attached to a stationary pin  114   a . Thus, the first latch element  110  is continuously urged toward its position of latching engagement with the second latch element  112 . To open the latch, a motor driven cam  115  is rotated to lift the second latch element  112  away from the first latch element  110 , and then pivots the first latch element in a clockwise direction (as viewed in  FIG. 15 ) to pull the plate  100  to the right to bring the aperture  105  into register with the apertures  103  and  104  in the stationary plates. This opens the key entry door so that a customer can insert a key into the key entry slot  104 . Continued rotation of the cam allows the first latch element  110  to pivot in a counterclockwise direction, returning to its original closed position under the urging of the spring  114 . 
     When it is desired to have the customer remove the key from the key entry slot, the drive motor for the cam  115  is energized to return the cam to its original position, thereby allowing the spring  114  to return the first latch element to its latched position, which in turn slides the plate  100  to its closed position. Returning the cam  115  to its original position also allows the second latch element  112  to return to engagement with the first latch element  110 , thereby securing the movable plate  100  in its closed position. The latch provides protection against tampering or vandalism. 
       FIGS. 17 through 26  illustrate an alignment mechanism  30  inside the kiosk for properly positioning a key inserted by a customer, to permit that key to be accurately evaluated and duplicated. The alignment mechanism  30  is shown in  FIGS. 17-26 . The mechanism  30  is shown in its fully retracted position in  FIG. 17 ; in its intermediate, low-force position in  FIGS. 22 and 23 ; and in its fully advanced, high-force position in  FIGS. 20 and 24 . The alignment mechanism includes a lower block  31  that is mounted for sliding movement along a rail  32 . A pair of low-force springs  33  and  34  maintain a space between the lower block  31  and an upper block  35 , which in turn is attached to a drive screw  36  that is threaded through the upper block  35  so that rotation of the drive screw  36  by a drive motor  37  moves the upper block  35  along an axis parallel to the rail  32 . The right-hand end of the lower block  31 , as viewed in  FIG. 21 , forms a horizontal slot  31   a  that receives the toothed edge of a master key inserted into the kiosk by a customer. Three horizontal pins P 1 -P 3  extend into the slot  31   a  and are urged toward the key K by light springs  51 - 53  similar to the tumbler springs in a lock. The upper block  35  also carries a high-force block  40  that is mounted for sliding movement on the uppermost surface of the upper block  35 , with a pair of high-force springs  43  and  44  (supported on rods  42   a  and  42   b ) urging the high-force block  40  to the right as viewed in  FIGS. 17 ,  20  and  21 . 
     From the time the kiosk first requests the customer to insert the key to be duplicated, the customer has approximately 60 seconds to insert a key into the slot  17 . During this time, the alignment mechanism  30  is in the “low-force” position, waiting for a key insertion. When the customer begins to insert a key into the slot  21 , an optical sensor  22  ( FIG. 18 ) adjacent the key-insertion slot  21  immediately detects the entry of the leading end of the key and produces a “Key Present” signal that causes the kiosk controller to start a 7-second time interval, so that action can be taken if full insertion of the key has not been completed within 7 seconds. That is, the customer is allowed 7 seconds to finish inserting the key into the slot. 
     While the master key K is being inserted into the kiosk, a pair of sensors produce signals that are used by the controller to determine whether the master key is possibly a type that can be duplicated by the kiosk. Specifically, as the master key K is inserted into the kiosk, the tip of the key engages and advances a slide  71  ( FIG. 19 ) against the biasing force of a spring  72  that urges the slide against the end of the key K, as shown in  FIG. 19 . The slide  71  carries two tabs  71   a  and  71   b  projecting laterally from the slide  71  to pass through a pair of corresponding optical sensors  73   a  and  73   b . The narrower tab  71   a  trips the sensor  73   a  to indicate whether the key length is within a prescribed range of acceptable key lengths, and the wider tab  71   b  trips the sensor  73   b  if the key length is too long to be duplicated by the kiosk. 
     Before the key K engages the slide  71 , the two tabs  71   a  and  71   b  are outside their respective optical sensors  73   a  and  73   b . After the key K engages the slide  71  and begins to advance it, to the right as viewed in  FIG. 19 , the narrow tab  71   a  enters the sensor  73   a  and interrupts the light beam of that sensor until the slide  43  has been advanced through a distance equal to the width of the tab  71   a . Thus, the time interval during which the light beam is interrupted corresponds to a preselected range of movement of the slide  71 , which in turn corresponds to a range of key lengths. If the master key K inserted by the customer falls within this range, the controller produces a “Correct Range” signal. If the master key K does not fall within this range, it is not a key type that can be duplicated by the kiosk. 
     The wide tab  71   b  enters its sensor  73   b  slightly before the narrow tab  71   a  exits from the light beam in the sensor  73   a , so if the light beam in the sensor  73   b  is interrupted at the time the narrow tab exits from its light beam, the two sensor outputs indicate that the master key K is too long rather than too short. In this event, the controller immediately generates a signal that causes the display of a message informing the customer that “We Cannot Copy Your Key,” without waiting for the time-out of the 7-second interval. As long as neither of the two light beams has been interrupted, insertion of the key might not yet be completed, so no message is generated until the 7-second interval has expired. If at that time neither light beam has been interrupted, the controller generates the “We Cannot Copy Your Key” message. 
     Full insertion of the key is detected by a sensor  23  (see  FIG. 27 ) that sends a signal to the kiosk controller when the top shoulder of the key K reaches a predetermined advanced position. Specifically, in the illustrated embodiment, the left-hand (“top”) shoulder of the key (as viewed from the front of the kiosk) engages a first sensor arm  23   a  to move a stub shaft  23   b  to a different angular position with respect to a shaft  23   e . This in turn moves a tab on the end of a second sensor arm  23   c  into an optical sensor  23   d . This causes the optical sensor  23   d  to send a “Key Fully Inserted” signal to the controller to indicate that the master key has been fully inserted into the kiosk. The two sensor arms  23   a  and  23   c  both pivot around the shaft  23   e , with the tab on the arm  23   c  being located farther from the shaft  23   e  than the stub shaft  23   b , so that a small angular movement of the arm  23   a  results in a much larger angular movement of the arm  23   c  and its tab. 
     If the controller does receive a “Key Fully Inserted” signal, a “Correct Range” signal and a “Key Present” signal within the 7-second time interval, the controller changes the display to “We cannot copy your key,” and the order is canceled. If the controller receives a “Key Fully Inserted” signal, a “Correct Range” signal and a “Key Present” signal within the 7-second time interval, the controller causes the key-alignment mechanism  30  to be moved to its fully advanced, “high-force” position to precisely position the fully inserted key before it is clamped in place for the duplicating process. If the controller determines that the key cannot be duplicated by the kiosk because the inserted key is too long, it immediately informs the customer that “We cannot copy your key.” If the controller determines that the inserted key cannot be duplicated by the kiosk because the inserted key is too short, the kiosk controller waits until the 7-second interval has expired, and if nothing changes before that interval expires, the display is changed to inform the customer that “We cannot copy your key,” and directing the customer to remove the key from the kiosk. 
     If the kiosk controller determines that the master key K may possibly be duplicated, the drive screw motor  37  of the alignment mechanism  30  is energized to turn the drive screw  36  to advance the upper block  35  to the position shown in  FIGS. 20 and 24 . In this position, the high-force springs  43  and  44  are compressed between the upper block  35  and the high-force block  40 , thereby moving the high-force block  40  and a pin rocker arm  41  to the right. The rocker arm  41  slides on the top surface of the lower block  31  and is coupled to the two end pins P 1  and P 3  by a pair of vertical pins  41   a  and  41   b . Thus, the force of the springs  43  and  44  is transmitted to the key K via the block  40 , the rocker arm  41 , and the vertical pins  41   a  and  41   b  that extend through respective slots  31   a  and  31   b  in the block  31  to permit sliding movement of the pins  41   a  and  41   b  relative to the block  31 . The middle pin P 2  is also biased against the key K by its spring S 2 , but is not subjected to the force of the springs  43  and  44 . The purpose of the rocker arm  41  is to permit the two end pins P 1  and P 3  to move relative to each other so that they can engage notches of different depths in the toothed edge of the master key K. Thus, the force of the springs  43  and  44  is applied to the toothed edge of the key K at two spaced locations, via pins P 1  and P 3 , thereby ensuring that the opposite (straight) edge of the master key is pressed firmly against a vertical alignment wall  49  on the lower clamp  50 . This completes the precise alignment of the master key K, so that it can be clamped to prevent any movement of the master key while it is analyzed and duplicated. 
     The two end pins P 1  and P 3  are beveled on both sides to form a straight vertical edge that engages the master key K and urges the key against the alignment wall  49 . Because the vertical edges on the ends of the pins P 1  and P 3  engage the key K along the entire height of the edge surface of the key, there is no risk of tilting the key as it is pushed against the alignment wall  49 , as depicted in  FIGS. 25 and 26 . 
     An upper clamp  51  is then lowered into engagement with the upper surface of the master key K to clamp the key tightly against the lower clamp  50 . The master key remains in this firmly clamped condition while (1) the position of the clamped key is checked to determine whether the key shifted during clamping, (2) the alignment mechanism is moved to its fully retracted position if the key remained in position, (3) the cross-sectional profile of the master key is identified, (4) a blank key having the design selected by the customer and also having the same cross sectional profile (same key type) as the master key is extracted from the blank-key magazines, (5) the extracted blank key is cut to have the same tooth pattern as the master key, (6) the new key is de-burred, (7) the new key is dropped into the duplicate key discharge tray  15  for delivery to the customer and (8) any key chains or other options are dispensed if they were ordered. 
     The master key clamp is shown in  FIGS. 17-18  and  28 , which depict a master key K being inserted, and then clamped, between the lower clamp  50  and the upper clamp  51 . The upper clamp  51  is attached to a vertical shaft  53  that carries a coil spring  54  that applies a constant strong downward force to the shaft  53 , which pulls the upper clamp  51  downwardly toward the lower clamp  50 . To open the clamp, against the downward biasing force of the spring  54 , a motor  55  turns a gear  56 , which turns a meshing gear  57  that carries a cam  58 . The cam surface  58  engages a cam follower  59  on the lower end of a shaft  53  so that the cam follower  59  is pulled down against the cam surface  58  by the force of the spring  54 . When the cam follower  59  is registered with the valley  58   b  of the cam surface  58 , the force of the spring  54  pulls the upper clamp  51  down tightly against the key K, thereby clamping the key tightly against the lower clamp  50 . By controlling the motor  55  to rotate the gear  52  by a certain number of degrees, the cam follower  59  is aligned with a peak  58   a  of the cam surface  58 , which raises the shaft  53  and the upper clamp  51  to open the clamping assembly and thereby release the key K. 
     To control the angular position of the cam follower  59 , a pair of optical sensors  160  and  161  supply signals to the controller when a tab  162  on a collar  163  connected to the output shaft of the motor  55  passes through the sensors. While the tab  162  is moving from sensor  160  to sensor  161 , the cam follower  59  is riding over the peak  58   a  on the cm surface  58 , which is the interval during which the key clamp is open. Thus, the motor  55  can be precisely controlled to open and close the clamp. 
     The “Key Present” signal mentioned above is produced by an optical sensor  22  built into the master-key clamping assembly. Specifically, a light source  22   a  is built into the lower clamp  50  and a photodetector  22   b  is built into the upper clamp  51 , with the light beam  21  passing through the master-key slot between the two clamps. Thus, when a master key is inserted between the two clamps  50  and  51 , the light beam is interrupted, and the sensor supplies a corresponding output signal to the controller. 
     To check the position of the key after it has been clamped, the kiosk controller checks the signals from the “Key-Fully Inserted” sensor  23 , the two length sensors  45   a  and  45   b  and the “Key Present” sensor  22 . If the kiosk controller determines that the position of the key did not change during clamping, the controller causes the alignment mechanism  30  to fully retract by energizing the drive screw motor  37  to turn the drive screw  36  in the reverse direction. If the kiosk controller determines that the key position did change during clamping, the controller causes the alignment mechanism  30  to return from the high-force position to the low-force position, causes the master-key clamping assembly to be released, and changes the kiosk display to a screen that directs the customer to “Insert and Hold Your Key.” This re-starts the entire process described above, starting with insertion of a key by the customer. If the customer re-inserts the key and the position of the key again changes during clamping, the kiosk changes the display to the screen to inform the customer that “We cannot copy your key,” and directing the customer to remove the key from the kiosk. 
     As described in U.S. Patent Publication No. 2008/0145163, the blade of the master key can have one of several different cross-sectional profiles, and identifying the profile of the master key effectively determines what type of key it is. Because only a limited number of different types of key blanks can be stored in the kiosk, the cross-sectional profile of the profile master key is matched against only preselected profiles, which are the profiles for which blanks are available in the kiosk. For example, a first profile may correspond to a Schlage key, a second profile may correspond to a Kwikset key, and a third profile may correspond to a Weiser key. Other key types may be identified with other corresponding profiles. 
     In the illustrative embodiment, the profile matching begins by engaging each side of the blade of the master key K with a plurality of gauges that correspond to the cross-sectional profile of one side of a specific type of key. Each gauge may have a profile that matches all or a portion of one of the grooves in a particular key type, or may simply sense the depth of the groove at a particular location that is common to several different key types, so that the combination of the depths at several different locations can be used to identify the key type. Referring to  FIGS. 29 and 30 , first and second gauges  60  and  61  extend through slots in the upper clamp  51  and are biased by springs  60   a  and  61   a  toward the upper surface of the master key K, and third and fourth gauges  62  and  63  extend through slots in the lower clamp  50  and are biased by springs  62   a  and  63   a  toward the lower surface of the master key K. A cam  64  has a first position (see  FIG. 30 ) in which it holds the four gauges  60 - 63  in retracted positions while the master key is inserted and aligned, and a second position (see  FIG. 29 ) in which the four gauges  60 - 63  are released to allow their biasing springs to move the gauges into advanced positions where they engage opposite sides of the master key K. The cam  64  is rotated between its first and second positions by a drive motor  65 . 
     The four gauges  60 - 63  are all mounted for pivoting movement around a common shaft  66 , for movement between their retracted and advanced positions. The left-hand ends of the four gauges  60 - 63 , as viewed in  FIGS. 29 and 30 , are profiled to gauge the shape of the engaged surfaces of the blade of the master key K, and the right-hand ends of the gauges  60 - 63  move through four separate optical sensors  67 - 70  to detect the angular position of each gauge when it is engaging the master key. Each of the sensors  67 - 70  produces an output signal when the advanced position of its gauge corresponds to the cross-sectional profile of one of the preselected key types, which allows the matching gauge to pivot into the grooves that form the cross-sectional profile of the blade of the master key. This additional pivoting movement of a matching gauge causes the right-hand end of that gauge to move into register with its sensor, causing that sensor to produce a signal that is used by the kiosk controller to identify the type of master key in the clamp. Thus, each of the different preselected key types is identified by a different combination of output signals from the four sensors  67 - 70 . The relatively small additional pivoting movement of the left-hand end of a gauge when it matches the profile of the key blade is amplified at the right-hand end of that gauge because of the longer lever arms of the gauges on the right side of the shaft  66 . 
     If the combination of output signals from the four sensors  67 - 70  does not correspond to one of the preselected key types, the kiosk controller changes the display to the screen that informs the customer that the key inserted by the customer cannot be duplicated by the kiosk and that the customer should remove the key, and the master key clamp is released to permit removal of the key. If the combination of output signals does correspond to one of the preselected key types, the kiosk controller aligns that particular type of key blank in the key-blank magazine  80  with the key-blank extraction mechanism. If the magazine contains that type of key-blank in different styles, the particular style selected by the customer is aligned with the extraction mechanism. 
     As can be seen in FIGS.  31  and  41 - 42 , the key-blank magazine  80  is mounted for lateral movement on a frame  81  at the rear of the interior of the kiosk. The magazine  80  slides on a stationary horizontal rail  82  attached to the frame  81 , and a drive screw  83  threaded through a bracket  84  projecting from the back of the magazine  80  is rotated by a reversible drive motor  85  ( FIG. 42 ) to move the magazine  80  in either direction along the rail  82 . After identification of the particular type of key blank needed to reproduce the master key, and the style selected by the customer, the kiosk controller energizes the motor  85  to move the magazine  80  to align that particular type and style of key blank with a key-blank extractor  86  (see  FIGS. 43-46 ). The key blank B extracted from the magazine  80  is always the bottom key in the particular magazine compartment that contains a stack of key blanks of the type and style selected, and each magazine compartment has an aperture  87  in the back wall of the magazine to permit the extractor  86  to enter the magazine  80  and engage the lowermost key in the particular compartment that has been moved into alignment with the extractor. 
     The magazine  80  is also moved to pass each of the multiple vertical channels past an optical sensor  93  to detect when the supply of blanks in any channel drops below the level of the sensor, e.g., a height of 40 key blanks above the bottom of the magazine. As long as any given channel contains at least 40 keys, a light beam directed to the sensor  93  from a source behind the magazine  80  is interrupted by the stack of blanks in that channel. But when the supply of keys in a given channel drops below 40, the light beam is no longer interrupted, and thus the sensor  93  changes state to indicate that the supply of blanks in that channel is low and should be replenished. 
     In the illustrative embodiment, the extractor  86  is in the form of a flat bar that has a flat front end  86   a  that abuts a corresponding flat  86   b  on the top of each key blank. As a key blank B is pushed forwardly out of the magazine by the extractor  86 , a taper  86   c  (see  FIGS. 45 and 46 ) on the top surface of the extractor engages and slightly lifts the key blank directly above the blank being extracted to maintain a slight space between those two blanks, to avoid any drag on the blank being extracted from the weight of the stack of other blanks in that same compartment. This helps keep the extracted blank B moving along a straight line. 
     Referring to  FIGS. 45 and 46 , the key blanks preferably have special features that enable the controlled, accurate and precise movement of keys from manufacturing to cutting. As already mentioned, the head of the key blank B has a flat end surface  86   b  for engaging the flat front and surface  86   a  of the extractor  86 . In addition, the head of the key blank B has long straight parallel sides  81  and  82 , and a preselected width that does not exceed the width of the magazine channel. All these features are used to help guide the key blank B along a straight path as the blank is moved out of the magazine and into the clamping mechanism for the extracted blank. 
     To avoid errors when loading the key blanks into the magazine  80 , such as inserting a particular type of blank or style of blank into the wrong compartment, and/or inserting a blank upside down in the correct compartment, the blanks have specific features that physically block any given blank from entering the wrong compartment and also block a key from entering the correct compartment but up-side-down. For example, as can be seen in  FIGS. 31 and 32 , key blanks are loaded into the magazine from the top of each compartment, and the access opening  87  at the top of each compartment is profiled to permit only blanks that match the profiled opening to be loaded into that compartment. The features used to distinguish the different types of blanks from each other for the loading profiles are primarily the shapes and dimensions of the head portions of the blanks. 
     To assist in the loading of different styles of blanks of the same type, a cavity  87   a  is provided at the top of the rear surface of each compartment to receive a sample  87   b  of the blank to be loaded into each compartment, as shown in  FIGS. 31 and 32 . Thus, the person loading the blanks can simply look at the samples to determine which compartment is to be loaded with blanks of any given style for any given type of blank. 
     To expedite the loading of the key blanks, the manual loading tool shown in  FIGS. 33-38  can be used to quickly remove the entire contents of a box of blanks and load them into the magazine  80  as a single unit, in a one-step operation. This tool has a compartment  300  that is open at one end for receiving the blade portions of a batch of a predetermined number of blanks, e.g., 40 blanks, packaged in a box  301 . The blanks are preferably packaged so that the entire stack of blanks in any given box has a dimension that matches the width of the tool compartment  300 . That is, a box of thinner blanks will contain more blanks than a box of thicker blanks, so that the overall dimension of the stacked thicknesses will be substantially the same for all boxes even though they contain different types of blanks. This permits the use of a single universal tool. 
     The box  301  has spacers at opposite ends of the packaged batch of blanks to provide spaces for receiving a pair of tabs  304  and  305  projecting from opposite ends of the compartment  300 . All the keys in a given box have the same orientation and length. A spring-loaded gripper  306  is manually opened slightly while the tabs  304 ,  305  are inserted into the box of blanks, and then released so that the spring  307  closes the gripper  306  against the entire batch of key blanks. A small bump  308  is formed on the top edge of the blade of each key blank when it is manufactured, and these bumps are engaged by a lip  309  on the free end of the gripper  306  to enable the entire batch of blanks to be captured and held together within the tool as they are removed from the box, transferred to the magazine, and loaded into the magazine. If a blank is oriented in the wrong direction, it will not be gripped and likely will drop out of the gripped stack, thereby avoiding the loading of that blank into the magazine. The bump  308  on each blank is ultimately removed as a part of the cutting operation that forms the desired tooth profile in the blank within the kiosk, as described in detail below. 
       FIGS. 35-38  show a key blank  400  custom made for use in the illustrative kiosk. For home and office keys, the shoulder  401  typically is the reference location for the X-direction (longitudinal direction). The shoulder  401  is typically referred to as the “top” shoulder in the key industry because it is on the toothed side of the key, which is normally the top edge of the key when it is inserted in a lock. This is the reference “stop” when a key is used in a lock and thus should also be used during duplication. 
     There are many key blank and key machine manufacturers, and they can and do manufacture their keys with different lengths and bottom shoulder locations. As such, conventional home and office key duplication theory discourages the referencing of key blanks using the bottom shoulder and/or the tip of the key, as it may result in keys that do not function. However, in the illustrative kiosk, the bottom shoulder and the tip of the extracted key blank are used as reference locations because the dimensions of the key blanks are controlled during the custom manufacture of those blanks. Specifically, the distance between the top shoulder and the tip, and the distance between the top shoulder and the bottom shoulder, are both controlled so that these dimensions may be used to control the position of a blank as it is automatically manipulated within the kiosk to ensure that the top shoulder of the blank is aligned in the correct location before that blank is cut. 
     Referring to  FIGS. 39-46 , as a blank B is pushed out of the magazine  80 , the blade of the extracted blank enters a clamp assembly  90  that is similar in operation to the clamp assembly described above for the master key. As the extracted blank B is pushed into the slot between the upper clamp  90   a  and the lower clamp  90   b , the outboard (top) edge of the blade of the key blank engages a guide roller  88  that has a circumferential channel or groove for ensuring proper guidance and alignment of the blank in the clamp assembly  90 . The guide roller  88  is journaled on the end of an arm  88   a  that is pivotably attached to the kiosk frame at  89  and is biased to pivot toward the clamp assembly  90  by a spring  88   b . The arm  88   a  passes through a sensor  88   c  that indicates when it is moved outwardly by a key blank, to produce a “Blank Present” signal that is sent to the kiosk controller (see  FIGS. 43 and 44 ). 
     The clamp assembly  90  is open while the extracted key blank B is being advanced between the upper and lower clamps  90   a ,  90   b , and an optical sensor in the clamp assembly  90  detects the entry of the blank into the clamp assembly and produces a “Blank Present” signal that is sent to the kiosk controller. The optical sensor  91  is built into the clamp assembly  90 . Specifically, a light source  91   a  is built into the lower clamp  90   b  and a photodetector  91   b  is built into the upper clamp  90   a , with the light beam passing through the key-blank slot between the two clamps. Thus, when the key blank being extracted enters between the two clamps  90   a  and  90   b , the sensor is tripped by interruption of the light beam. 
     The final position at which the key blank B stops within the clamp assembly  90  is determined by one of two or more different stops. For longer key blanks, the tip of the blade of the key blank engages a stop block  92  on the front side of the clamp assembly  90 . For shorter key blanks, the left-hand (bottom) shoulder of the key blank, as viewed from the front of the kiosk, engages the rear side wall of the lower clamp  90   b . After the key-blank extractor  86  has reached its most advanced position, and the “Blank Present” signal is still present, the clamp assembly  90  is closed by lowering the upper clamp  90   a , in the same manner described above for the master key clamp assembly, to press the key blank tightly down against the lower clamp  90   b . The key blank is then ready to be cut to reproduce the clamped master key. 
     Referring next to  FIGS. 48-59 , the edge of the key blank B that protrudes from the clamp assembly  90  is cut by a cutting wheel  131  (see FIGS.  56  and  58 - 59 ). During the cutting of the selected key blank, the master key and the cutting wheel  131  remain in fixed positions, while the key blank B to be cut and a follower  132  for tracing the tooth pattern on the master key move as a single unit along an axis that is parallel to the axes of the blades of the clamped master key K and the clamped key blank B. Specifically, the key-blank clamp assembly  90  and the follower  132  are both mounted on a base  133 , which in turn is mounted on a carrier  134  that is driven along a rail  135  by a motor  136  that turns a drive screw  137  threaded through the carrier  134 . Movement of the carrier  134  along the rail  135  moves both the key-blank clamp assembly  90  and the follower  132  in unison along an axis parallel to the axes of the blades of the clamped key and key blank. To permit movement of the blank clamp assembly  90  and the follower  132  in a direction substantially perpendicular to the axes of the blades of the clamped key and key blank, the base  133  is mounted on a shaft  138  journaled in the carrier  134 , with a spring  139  urging the base  133  to pivot about the shaft  138  in a clockwise direction as viewed in  FIGS. 48-55 . This spring bias on the base  133  enables the follower  132  to follow the tooth pattern of the master key K, and enables the clamped key blank B to follow the pattern of movement of the follower  132  as the follower traverses the length of the blade of the master key K. Thus, the cutting wheel  131  cuts a tooth pattern in the clamped key blank B that reproduces the tooth pattern of the master key K, as depicted in  FIGS. 58 and 59 . 
     As can be seen in  FIGS. 58 and 59 , the cutting wheel  131  is oriented with an angled edge  131   a  facing the clamped key blank B.  FIG. 59  shows the system in mid-operation with a portion of the tooth profile of the master key K already reproduced in the key blank B. 
     When the follower  132  is not aligned with the master key K, pivoting movement of the base  133  about the shaft  138  is limited by a cam  140 , as shown in  FIGS. 48-55 . In addition, the cam  140  can be rotated to different positions to pivot the base  133 , about the shaft  138 , to retract the follower  132  and the key-blank clamp assembly  90  to positions where the follower  132  and the key blank B cannot engage the master key K and the cutting wheel  131 , respectively. The different angular positions of the cam  140 , and thus the base  133 , during different stages of a key-duplicating process, are shown in  FIGS. 48-55 . In  FIGS. 30-48 , the cam  140  is in its intermediate position where the base  133  is level, while the extracted key blank B is being clamped. In  FIG. 49 , the cam  140  is in its high position where the base  133  is tilted back, away from the cam  140  and against the bias of the spring  139 , while the carrier  134  moves the clamped key blank into alignment with the cutting wheel  131  and the follower  132  into alignment with the clamped master key K and moves the follower  132  along the master key. 
       FIG. 50  shows the clamped key blank B aligned with the cutting wheel  131  and the follower  132  aligned with the master key K, with the cam  140  still in its high position. In  FIG. 51 , the cam  140  is in its low position where the base  133  is tilted forward, toward the cam  140 , so that the spring  139  urges the key blank B against the cutting wheel  131 , and also urges the follower  132  against the master key K, while the carrier  134  moves the follower along the blade of the master key K, and the blade of the key blank B across the cutting wheel  131 , to cut a tooth pattern in the key blank that reproduces the tooth pattern of the master key. The tooth profiles of the clamped master key K and the clamped key blank B can be seen more clearly in the enlarged top plan views of this key-duplicating operation in  FIGS. 58 and 59 . 
     In  FIG. 48 , the cam  140  is in its intermediate position where the base  133  is level, while the extracted key blank B is being clamped.  FIG. 53  shows the cut key blank B aligned with the de-burring (e.g., wire-brush) wheel  141 , with the cam  140  is still in its high position. In  FIG. 54 , the cam  140  has been returned to its low position where the base  133  is tilted toward the cam  140 , while the de-burring wheel  140  is driven to clean debris from the freshly cut teeth. After de-burring, the duplicate key is discharged from the clamp assembly by opening the clamp and energizing a solenoid to move an ejector pin  142 . In  FIG. 55 , the carrier has been returned to its starting position where the key blank was first clamped. The ejected duplicate key slides down a dispensing chute  143  into the duplicate-key output tray  15  in the front of the kiosk. 
     Most of the key-cutting wheel  131  and the de-burring wheel  141  are enclosed in respective vacuum shrouds  144  and  145  coupled to a common vacuum source for removing debris caused by the cutting process. The two vacuum shrouds  144  and  145  are coupled to the common vacuum source by respective conduits  147  and  148 , both of which join a single conduit  149  leading to the vacuum source. As can be seen in  FIG. 60 , the only parts of the cutting wheel  131  and de-burring wheel  141  that are not enclosed by the respective shrouds  144  and  145  are the segments of the wheel surfaces that engage the key blank to cut and de-burr the teeth of the duplicate key. In the illustrative embodiment, the cutting wheel  131  and the de-burring wheel  141  are mounted on two separate shafts  150  and  151 . The axis of the de-burring-wheel shaft  151  is positioned slightly below the key blank, and the de-burring wheel shaft  151  is rotated in a direction opposite that of the cutting-wheel shaft  150  so that the tooth edges of the key blank that are first engaged by the de-burring wheel  141  are the edges last engaged by the cutting wheel  131 , which are the edges that contain any burrs or other debris remaining from the cutting operation. 
     A small digital video camera, e.g., a webcam, is mounted in the interior of the kiosk for recording and transmitting video and photo images of different regions of the interior of the kiosk. These video images may be used for different purposes, such as troubleshooting a kiosk that has reported a malfunction such as an inability to complete a preselected number of customer-initiated transactions within a preselected time period, repairing detected malfunctions, monitoring the condition of parts that need periodic replacement such as cutting tools and cleaning brushes, monitoring the condition of items that require maintenance such as the vacuum system that accumulates the debris from the cutting and brushing operations, monitoring the numbers of different types of key blanks remaining in the key-blank magazines, etc. The video output of the digital video camera is coupled to the cell modem, for periodic transmission to the server  210  in the central office  204  and/or to a local service provider for a number of kiosks within a given geographic region. The video camera can also be remotely controlled for producing video images upon receipt of command signals from a remote computer such as the server  201 . Video images from the camera can also be transmitted to the kiosk display, to replace or supplement the viewing window in the kiosk that allows customers to view the key-duplicating operations. 
     For example, if an error report is sent regarding malfunctioning sensors in the kiosk, the webcam allows a remote user to monitor the robot through the webcam and help determine which sensors are not working properly. The remote user can then remotely control the kiosk, or reset or re-initialize the kiosk if necessary. In addition to being able to monitor everything that is going on within the kiosk, the webcam can take high resolution photographs of a problematic area, which can then be further analyzed at a remote location to determine what mitigation steps need to be taken. For example, if the webcam shows that a key is jammed in the kiosk, that problem can be fixed by remotely commanding the kiosk to eject the jammed key. 
       FIG. 61  is a diagram of a network of multiple interactive, key-duplicating kiosks  200   a ,  200   b  . . .  200   n  communicating with a remote server  201  via the communication interface  24   b  in each kiosk. The communication interface  24   b  in each kiosk connects that kiosk to a network  213  such as the Internet or a local network with Internet access. A computer system  204  in a remote central office has access via communication lines  205  and  206  to the server  201 , which receives, stores and compiles data from all the kiosks  200   a - 200   n  and reports back to the central office computer system  204 . 
     The kiosks  200   a - 200   n  communicate independently with a credit card payment processor  207  via communication line  208 . The credit card payment processor  207  may also communicate with the central office  204  via lines  211  and  212 . Upon reading customers&#39; credit cards during the payment processes, the kiosks  200   a - 200   n  send the credit card data through a wireless connection to the processor  207 , which checks to see if each card is authorized for the requested amount and reports the result to the kiosk. When a request for credit card payment reports is sent to the processor  207  from the central office via line  211 , the payment processor  207  sends back the requested credit card payment notification via line  212 . 
     The individual kiosks  200   a - 200   n  also communicate independently with individual customers  209  via communication line  210 , such as when a kiosk sends an email receipt of a completed transaction to the customer at the email address supplied to the kiosk by that customer. 
     The server  201  maintains a list of all the kiosks available for remote access, and enables a connection to be made between the central office computer  204  and any kiosk linked to the server  201 . This allows for close monitoring of the kiosks and provides the capability of remotely managing most issues that can arise with the kiosks  200   a - 200   n . The kiosks periodically report order transaction information and error information to the server  201  via communication line  202 . The order transaction information includes details of every completed transaction. The error information includes any technical, mechanical, electrical or other issues that a kiosk is experiencing, or has experienced. When the server  201  receives error information, it automatically sends an email notification regarding the errors to the central office  204 . The server also maintains recorded information about each customer&#39;s keyway and key profile, allowing customers to later request a copy of their key to be mailed to them. 
     Examples of information automatically reported by each kiosk  200   a - 200   n  to the remote server  201  are “invalid keyways” detected on master keys (which means such keys cannot be duplicated in the kiosks), the insertion of master keys that are too long or too short to be duplicated in the kiosks, detected misalignment of a master key after clamping, credit card rejections, insertions of credit cards that could not be read, etc. All this data is analyzed, either in the server  201  or in the central office computer, and reports of the results of these analyses are generated and either distributed automatically or stored for periodic reviews by authorized personnel. For example, one type of report compares the data collected from any given kiosk with the same type of data from other kiosks in a similar market or geographical region, or even all the other kiosks in the network. Another type of report compares the latest data from a given kiosk with the historical averages of the same types of data from that same kiosk, so that deviations from chronological trends can be detected and analyzed, and alerts can be generated if the current data falls outside an acceptable range. 
     For example, if a problem develops with the keyway identification system in a given kiosk, causing that kiosk to generate false rejections, the average percentage of master keys, and thus customers, that are rejected will increase for that kiosk. This increase will appear in the “health” reports for that kiosk, which can then be inspected, virtually and/or physically. 
     The kiosks  200   a - 200   n  also conduct self tests and report the results to the remote server  201 . For example, after each order, readings are taken from all the sensors and compared to predetermined thresholds or ranges representing normal operation of each sensor. If the reading taken from any sensor deviates from the predetermined threshold or range, that sensor may not be functioning, not functioning properly, or even have a design flaw. Such a reading may also be indicative of malfunctioning hardware. Regular reporting of the results of the automatic self tests enable early detection and correction of such issues, thereby reducing the down time for all the networked kiosks. 
     Another example of a self test is the automatic cycling of moving parts in the kiosk at predetermined times to determine whether those parts successfully move to known positions within a specified time intervals. These self tests can test whether a specific motor is moving, whether a specific part is moving, whether specific movements occur within the specified time intervals, whether specific sensors are functional, etc. If any of the preselected criteria are not met in these self tests, the kiosk automatically sends an alert to the remote server so that the part in question can be quickly inspected and corrective action taken. 
     After an error has been corrected, a remote user in the central office may virtually run a test sequence to confirm that the problem has indeed been rectified. The server also allows troubleshooting of software-related issues, and can be used to update the software in the kiosks. Promotions and advertisements the customer sees on the kiosk display screen can also be updated and controlled via the server  201 . 
     Other communications sent by the kiosks through the server  201  include daily sales and transaction reports which contain a compilation of sales and transaction data, including the total number of transactions and the corresponding dollar amount, for the day. These reports also help maintain the key blank inventory. If a key blank magazine, or certain compartments of a magazine, are reported as being depleted or low on stock, the webcam may be used to confirm the stock level and updates can then be made accordingly. The central server  201  can also monitor and correlate data from each kiosk with data from other sources, such as reports from the facilities in which the kiosks are located and historical records maintained for each kiosk. For example, returns of duplicate keys made by the kiosks are handled by customer calls to a toll-free number, and the server  201  maintains a rate-of-return record for each individual kiosk and for different groups of kiosks, e.g., by retail organization and/or by geographical region. An increase in the rate-of-return for a particular kiosk by more than a certain amount above the average for all kiosks indicates that a problem might exist for that particular kiosk and, therefore, it should be inspected. Another example is comparing the rate of rejection of customers, based on the insertion of keys having unsupported keyways, by a particular kiosk compared with other kiosks located in similar markets or stores. The maintenance record of each kiosk may also be periodically compared with other kiosks of similar age and usage rates. The results of these and other analyses can be used to identify issues before they become serious and before they have a significant effect on sales and/or relationships with store personnel 
     Kiosks of the type described above are capable of providing return rates of less than 1%, and the time required to produce a single duplicate of a master key is less than one minute. The remote communication system permits these and other performance parameters to be continuously monitored, so that any deviation can be promptly detected, and corrective actions can also be taken promptly. Mis-cut returns for each kiosk can be monitored in near real time by matching the customer making a return to the time, date and location of the kiosk used to make the returned key, and building a mis-cut timeline for each kiosk. Field personnel can also be provided with special master keys that are used to make duplicate keys that are returned to the central office for measurement and analysis for any corrective action that might be needed. 
     The remote communication system can minimize down time for all deployed kiosks by monitoring alert signals generated automatically by each kiosk when a questionable condition is detected. These signals can be investigated immediately by central office personnel who can take the necessary corrective action to ensure that a kiosk that sent an alert does not go down, or to promptly restore that kiosk to normal operation. This central-office monitoring and remote fixing reduces reaction time and also provides more consistent and accurate maintenance by a field personnel with more limited experience on many issues that arise in maintaining a kiosk, as compared with highly trained personnel in the central office. Central remote fixing allows experts located at the central office to obtain a large amount of detailed information about a kiosk and use the webcam to quickly identify a problem while a field technician is dispatched to the machine. When the technician arrives on scene, the central office can send visual and audio demonstrations to the kiosk display to remotely guide the technician in efficiently resolving the problem. Central monitoring is also more effective in dealing with a problem, such as a bad lot of key blanks, that originates from a single source but results in problems distributed over a number of different kiosks. 
     While particular embodiments and applications of the present invention have been illustrated and described, it is to be understood that the invention is not limited to the precise construction and compositions disclosed herein and that various modifications, changes, and variations may be apparent from the foregoing descriptions without departing from the spirit and scope of the invention as defined in the appended claims. For example, the master key inserted by the customer could be analyzed and matched to an original code that is then used to control the cutting of the duplicate key(s), rather than using the master key as a real-time pattern for cutting the duplicate. In this case, the remote communication system could be used to pre-order the cutting of a duplicate key using a code identified by the customer. Another alternative is to add a printing station to create different styles of keys in the key, to avoid the need to store different styles of blanks for the same type.