CA2147515C - Method and apparatus for aligning and cutting single-sided and double-sided keys - Google Patents

Abstract

First and second cutter head assemblies each include a key follower positioned at a first elevation and a spaced apart cutting wheel positioned at a second elevation. The key followers trace the bitted surfaces of a master key while the cutting wheels move with the key followers and duplicate bitted surfaces of the master key onto a key blank. A linear displacement bearing assembly is coupled to the first and second cutter heads to permit the key followers and cutting wheels to be laterally displaced with respect to the master key and key blank.
A key positioning cassette system holds and aligns the master key and key blank relative to the first and second cutter head assemblies. Another linear displacement device is coupled to the base of the key cutting machine and to the cassette system for longitudinally displacing the key blank and the master key with respect to the longitudinally fixed key followers and cutting wheels. The various elements of the key cutting machine thus trace or follow the bitted surfaces of the master key and duplicate those bitted surfaces onto the bitted surfaces of the key blank.

Description

t. 2147Sl~
This application is a division of ~rrlir~ti~n serial number 2,001,084, filed October ~0, 1989 BACKGROUND OF THE IliVENTIO~

l. Field Qf the Invention This invention relates to key c~tting machine$, and more particularly, to key cutting ~--hint~C: which trace the bitted surfaces of a master key and t~-lrl ~ t~att~ them onto the bitted surface~s of a key blank, 2. Dest~-rir~tion of the Prior A~t ~ nited State$ Patent No. 3,43~, 535 (}I~ly'y~ L~ ~
t~;c,~lt~st~ a key cutting 2nachine having a single vertically t~ pl~;t~hlt~ key ft l lt, ~/cutting wheel assembly. A vice-like key retaining assembly clamps a master key and a key blank in a fixea position. This vice-like key retairling assembly completely :~ULL~UlldS and blocks the opposite or rear surfaces of both the master key and key blank preventing tracing of the rear bitted $urface of the _aster key as well as access to the rear bitted $urface of the key blank, A cam-like 1 -~h~ni~m displaces the master key and the key blank relative to the key follower and cutting wheel. An electric motor is coupled by a series of universal joints and a drive shaft to rotate the cutting wheel.
sefore either the key follower or the cutting wheel is moved iDto ~ '' -_ . . .

~ 21~7515 .
position to trace the single exposed bitted surface of the master key or to cut the single exposed bitted surface of the key blank, a gear driven key Ali~; -nt plunger 36 T- hAnir~lly contacts and forces the rear surface of the master key and key blank against the base of the vice-like key-holding device to appropriately align the master key and the key blank.

United States Patent No. 1,243,810 (Christoph~
d;~nl~5-~c a key cutting machine having a pair of rotary key cutting wheels which radially pivot about a pair of spaced!,apart pivot ~ to simul~An~o~Tc:ly cut bitted ~, r^~e~ into a two-sided key blank. This key cutting machine follows a sp~c~Ally ~..,LvuL~d, linear t lAte 10 and i8 in~lr~hl~ of following the first and second bitted D"~ r~ of a two-sided master key. The t _lAt~ inn~ a two-sided contour which at least in part ~ .L.j the inverse of the desired ~lrl i~nA~te key. This t _ l~te is dP~ n~-d to _ te ~or the circular, non-linear ,~ rlr of the two rotary cutting wheels about pivot points 33 and 36.

Even if the errors arising from the circular or radial di~rlA- ~ of the two cutting wheels relative to the key blank were disregarded, positioning a master key at the key fol 1 l ~
location of this key cutting device would reproduce cuts in the key blank exactly opposite or 180 ' out of phase with eh bitted surface of the master key due to the location of the follower on t . ~147Sl~
.
t e opposite side of a lever arm from the location of the cutting wheels. The use of this lever arm coupling system causes an upward displ ~ ( ~ caused by a master key bit to create a downward displ ~ or cut in the key blank and thus ~L u luces a mirror image of the master key bitted DU~ rC~C~S on the key blank.
Such a mirror image key would be inoperative to actuate a lock configured to be opened by the master key. Only by ~ rl ir~tinq a master key onto a key blank to produce a mirror image key blank, removing the mirror image key blank, relocating it in the master key position and duplicating the mirror image key blank on~o a second key blank coula an operative master key be ~L~du~=d.
Since this operative master key would have been ~L~duct:d as a second ~ ion master key two copies removed from the r~-iqin~7 master key ana since the Christoph key cutting machine fails to ,~ _ t for the radial, non-linear ~ P~ ~1rnA of the key cutting wheels relative to the key blank, the resulting duplicate master key would inc;uL~oL~te OUD, POt~nt;;~11Y F:~qn;f1I~tnt L~ ~L ~;~ion errors.

United Stateg Patent No. 4,651,604 (A1 ` 1A~ ;CÇ1~1C~C
a ~ c~ sed key ;.1~,~ device for a punch-activated key t~atl ~n system. The second bitted surface of a two-sided key can only be created by means of this ~-cc~ based ;~
system by removing the key blank, reversing it, reinserting it into the ~ cse~ and Ç~ntin--in~ to operate the punch -- iFm ~hile sey~ Lli-lly lc~=gil~ld~n~lly d1-1r7 o1n~ e l:~y bl;mlc ~4~i15 relative to the punch r- ~-n;~m to generate the a~Lv~Liate series of bits along the entire secona bitted surface of the key blank .
S~RY QF TT~ INV~NTIQN

It is therefore a primary object of the present invention to provide a key cutting machine capable of simul~AnPnuqly following the first and second bitted surfaces of a two-sided master key and simultAn~o~lcly duplicating those bitted ~ c onto the first and second bitted DuLra~.es ,of a two-sided key blank.

Another object of the present invention is to provide a key cutting machine having a key A~ irm housed in a removable key-holding cAccettP where one type of r~Accett~ can be coni~igured to align a single-sided master key and key blank while another type of ~ 6e ~ can be c~n~ red to align a two-sided master key and key blank.

Yet another ob; ect of the present invention i5 to provide a key cutting machine which - 1ichPq duplication of a master key onto a key blank during repetitive back and forth longitudinal r~ rlA~ ' of both a master key and a key blank.

Briefly stated, an in accord with one ~ ir ~ of the invention, a key cutting machine having a longitudinal axis and a 21~751~ i~
.
lateral axis duplicates a master key onto a key blank. The master key and key blank each include a length, an upper surface, a lower surface, a tip, a shoulder, and a first bitted surface.
The bitted surface of the master key inr.lllfl~c cuts extending laterally between a first lateral position and a second lateral position. The key cutting machine in~llul.os a base, a first cutter head having a first key follower positioned at a first elevation and a spaced apart first cutting wheel positioned at a secorid elevation as well as second cutter head i nclllfl i n~ a second key follower positioned at the first elevation and a spaced apart second cutting wheel positioned at the cecond elevation. First linear ~cpl~, means i8 coupled to the base and to the first and second cutter heads for simult:~n~ cly laterally ~ rlA~-1 the first key follower and the first cutting wheel toward and away from the first bitted ,,u, r~ces of the master key and the key blank between the first and second lateral positions to enable the ~irst cuter head to laterally follow and duplicate the first bitted ~uLrclces oi~ the master l~ey onto the first bitted ~urr~Lces of the key blank. Key positioning means is also provided which in~ A~c first key positioning means and second key positioning means. The first key positioning means positions the master key to engage the first and second key fol 1~ - at an indexed position where the first key follower initially engages the b~ginnln~ of the first bitted surface. The first key positioning means also maintains u ~ L~ uuled access to the first bitted surface of the master key as the key positioning means is ~l 21~7~1a _ longitudinally translated relative to the first key follower.
The second key positioning means positions the key blank to engage the first cutting wheel at an indexed position with the first cutting wheel initially engaging the key blank where the beginning of the first bitted surface of the master key is to be ~:~L~lu~ ~d. The second key positioning means also ln~int~inc ~,ob2,~Lu.;l.ed access to the first bitted surface of the key blank as the key positioning means is longi~ i n~ 1 1 y translated relative to the first and second cutting wheels. - The key cutting machine further in~71lr7r C second linear licr~ means aoupled to the base and to the key positioning means for longit~ldin~lly ~7~F:rl;~inq the first bitted surface of the master key re_ative to the first key fo71~ along the longitudinal axis at the first elevation. The second linear d i crl :tCI ' means also longitudinally dicrl~cr 5: the first bitted surface of the key blank relative to the first cutting wheel along the longitudinal axis at the second elevation to Lt~l~.luce the first bitted surrace q;E the master key on the first bitted surface of the key blank.

Briefly stated, and in accord with a second: ~ ' I
of the invention, a key ~ L device having a longitudinal axis and lateral axis laterally aligns a first key ;nr-71ldinq a length, upper and lower surfaces, a tip, a shoulder, a root and a " _ ` 21~7~1~
bitted surface OppOSite the root. The key ;~ device includes upper and lower clamping surfaces ~iCrlA~ ~Ahle between ~n open position for receiving the first key between the clamping surfaces and a closed position for ~n~a~i n~ the upper and lower surfaces of the first key and re~Ainin~ the first key in a fixed lateral position with a horizonal orientation. A root nl i~ -nt surface laterally offset on a first side of the ~1 _inq ~uLrGCèS
receives the key root and aligns the key root parallel to the longitudinal axis. Tip ;~ means engages the key tip and aligns the key tip against the root Al ~ j : s~rf~-e. 1ateral Ali,3 ~ means engages the first key at a first position ~CrlAC~ along the length of the key away from the key tip after the ~lr _'n~ D~lLrG~ S have been .licrlA,-~-l into the closed position. The lateral Ali ~ means also l~t~lly ~llcrlA~c~c the first Xey toward the root ~li~_ surface with a lateral force s~ 'ici~nt to V~ L~ the ~,1; _ ing forces exerted on the first key by the clamping surfaces until the key root c~ntA--tc the root ;~ surface to thereby align the key root with the root Al ~,3 ~ surface and with the longitudinal axis of the key ~1 i ,3 device.

Briefly stated, and in accord with another: -i of the invention, a key A1l~3 ~ device having a lnng~t~Ain:~l axis and a lateral axis laterally aligns a first key relative to a first defined, fixed centerline. The first key includes a length, upper and lower E;urfaces, a tip, a shank, first and -. 21~7515 second side surfaces and a centerline The key ~l i,3 ' device includes a first laterally ~giqrl;sc~Ahle jaw located on a first side of the first defined centerline at a variable distance D1 from the first defined centerline and engages the first side of the first key. A second laterally ~i~:rl~ hle jaw is located on a second side of the first defined centerline at a variable distance D2 from the first definea c~nt~rlin~ and engages the second of the first key. Jaw position control means is coupled to the first and second jaws and r~-int~inR distance Dl equal to distance D2 as the first and second jaws are laterally ~ ne toward or away from the first defined c~nt~rlin~. Jaw biasing means laterally biase~; the first and second jaws toward the first dei~ined c~ntDrlin~ with a lateral biasing force. The jaw biasing means also permits the first and second jaws to be l~t~r;tlly ~r~ d away from the first defined c-~nt-~rlin~ in LSs~, se to an oppoei n~ lateral force greater than the lateral biasing force.

, .
DES~RTPTION OF TED3 nR~WTNGS

The invention is pointed out with particularity in the -I~. d-d cla~=, l~o~evur, other ~ e~tt ~Dd adv~t~ges together 21~7~15~
with the operation of the invention will be better understood by reference to the following detailed description taken in connection with the following illustrations, wherein:

FIG 1 is a top view o~ the key cutting machine embodying the principles of the present invention with a housing cover and a key magazinQ removed to expose the interior components .

FIG. 2 is a side elevational view of the key cuttcing machine of FIG. 1 also with the cover removed.

FIG. 3 is a front elevational view of the key cutting machine of ~IG. 1 with the housing cover in place.

FIG. 4 i5 a rear elevational view o~ the key cutting machine of FIG. 3.

FIG. 5 is a perspective exploded view of the key rçceiving r-~7inF~

FIG. 6 is an f~Ypl orl~ perspective vlew of the cutter carriage.

E'IG. 7 is a side sectional view showing the key receiving clamps of the key r~ 7in lo 21~7~1~
_ FIG. 8 is a sectional view taken generally along the line VIII-VIII of PIG. 7.

FIG. 9 is an exploded perspective view of the key cutting machine housing.

FIG. 10 is a side elevational view of the Xey 1^~ in~.

FIG. 11 is a front view of the key r~ i n-~ with a front cover removed. fl FIG. 12 is a rear elevational view of the key ~-g~in~
with a rear cover removed.

FIG. 13 is a top ~ct innAl view of the key receiving in~- taken at the single sided key cla~p level, generally along the line XIII--XIII of FIG. 7.

FIG. 14 is a top view of the key receiving ~=~inc~
taken at the double sided key clamp level generally along the line XIV--XIV of FIG. 7.

FIG. 15 is a s~ctinnl~ view through the key ~ in~
portion of the key r~ in~ taken generally along the line XV-XV
of FIG. 7.

21~7Sl~ .
FIG. 16 repre3~nt3 a perspective view of a second P~ nt of the key autting maahine of the present invention 6howing the cassette removed f rom the key c~tting ~nachine .

FIG. 17 is a partially autaway perspective view Gf the key cutting machine of the pr~3ent inv~ntion 3howlng the cassette as installed.

FIG. i8 repre6ents a simpli~ied partiz-l ele~-tric ~chen~atic diagram Or the key cutting ~achine of the prese~nt invention .

FIG. 19 represents a sectional view of the icey cutting machine illu3trated in FIG. 16, 3howing t~e relative movement of one part o~ the key cutting machine relative to the~ other part during the key cutting operation.

"~ FIG. 20A repre~sents a partially cutaway ele~ational view of the cam drive system of the pre6ent invention at the be~lnnin~ of its cycle.

FIG. 20B represenl:6 a ~:e~ona view of the calT~ drive J3y~tem of the present invention showing the cam creating the maximum outward displaoement of the front section of the key cutting machine.

~ 21~15 _ FIG. 21 is an exploded perspective view illustrating the linear bearing system ana the cutting head of the present invention.

FIGS. 22A and 22B represent partially cutaway elevational views of the key cutting machine of the present invention particularly illustrating the linear bearing means of the present invention and the first and second cutter heads.

FIG. 23 Le:YL~S~IL~ a partially cutaway elevational view showing one linear bearing system of the present invention and the second cutter head assembly.

FIG. 24 LelJL~lLD a partially cut~way elevational view of a key ~ ett~.

FIG. 25 Lt~L~SeILLD an enlarged p~ y~l ive view of the upper and ~ower ~1; ,~n~ Lr~ce~s of the -~ e 1~ n~ed in FIG. 24.

FIGS. 26A and 26B illustrate the upper and lower ~1: ;n~ .~... r,..~ . of the present invention being ~ rl~t~ed between the open and closed positions.

FIG. 27 L~yL-:st:llLs a perspective view of the tip a ~ pl~mq oi the pre8ent ~nv~3tio=.

2147~15 FIG 28 Le~LesellL~ a partially cutaway elevational view of the end of the tip ~ plunger intended for use with a two-sided key.

FIG. 29 le~LèSell-~ a partially cutaway elevational view of the end of a tip Rl i ' plunger intended for use with a single-sided key.

FIGS. 30A and B Le~LeSéllL partially cutaway perspectivê
views of a key alignment device of the pre6ent invention i ntPn~lPd i~or use in cnnnPctisn with a two-sided key.

FIGS. 31 and 32 le~LeSel~ elevational and s~c ti~n~l views of a typical one-sided key.

FIG. 32 Le~LeSell~:~ an elevational view o~ a typical tWO~Sidêd key having a F:h~ Pr.

FIG. 33 is a sPc~inn~l view of the two-sided key trnted in FIG. 32, taking along section lines 33-33.

FIG. 34 Le~ esellLs an elevational view of a tWO~Sidêd key without a shoulder.

FIG. 35 e~LeSe lL~ a s~tinn~l view of the two--sided ~ - 214~
kçy illustrated in FIG. 34, taken along section lines 35-35.

FIG. 36 le~Les~l~t~ a partially cut away elevational view of the single-sided key alignment device.

FIG. 37 Le~esellL~ a partially cutaway elevational view showing a two-sided key being laterally aligned within one of the key A~ t device oE the present invention.

FIG. 38 is a partially cutaway pr~l-Rp~r~tlve view s,olely for the purpose of illustrating the relative relationship between the master key, the key blank, the key follower and the cutting wheel elçments of the present invention to illustrate the manner in which key duplication is a~ l;Rhr~i by the key cutting machine of the present invention.

FIG. 39 illustrates the manner in which the cuts of a master key~ are duplicated on a key blank by repetitive passes of a cutting wheel back and forth along the key blank.

FIGS. 40 and 41 LelJLe5ell~ partially cutaway elevational views showing the manner in which a key Ali~, ' device of the present invention intended for use with single-sided keys can be operated.

FIGS. 42 and 43 represents a partially cutaway ~5 -elevational views depicting the manner in which a key ~1; L
device of the present invention ia capable of laterally ~1 i Jni a single-sided key.

FIG. 44 is a simplified elevational view showing one potential form of damage which can occur to the key cutting - ~ i f ~ under certain ciL~ k.l~ceâ .

FIG. 45 is related to FIG. 44 and shows a protective -^h~ni.~ for preventing the damage illustrated in FIG. 44.,~

FIG. 46 Le~L~:8~ . a rr~ pr~ct ive view of a shim for ~LI ~ to a ~-A~ ette of the key cutting machine for properly longit~lAin;~lly ;17i~nin~ a F2h~ l~ss key.

FIG. 4~ J.e se,.L~ an enlarged, partially cutaway pe.a~e~;~ive view illustrating the fl1n~t~on of the key ;~
device for~ laterally ;~1 i~in~ single-sided keys.

FIGS. 48, 49A and 49B le:~L~S~ partially cutaway elevational views further illustrating the manner in which a key device of the present invention laterally aligns single-sided keys .

FIG. 50 illustrates a key A1;,; ' device for a two-~ided k~y includin(~ ey ~et p pg FIG. 51 ~ ~C~, a more detailed illustration of the PIG. 50 key ~ nt device, particularly illustrating the relative positioning of the cutter head, key follower, and cutter wheel s~ ~c~

FIGS. 52 and 53 illustrate yet another: ~'i of the key ~1 i; device for laterally i.l iqnin~ two-sided keys, cre~ y two-sided keys where the interior portion of the bitted surfaces is positioned close to the key head.

FIG. 54 illu"l~ tes another: 'i= of the key Al~cJning device of the present invention for ;lli~nin~ a two-sided key.

FIG. 55 i l l ~ tes another : - ~ i - of the key ~llqnin~ device of the present invention for i~liqnin~ a two-sided key FIGS. 56 and 57 illustrate yet another key device for laterally ~1 iqnin~ a key U~Sc.K~ c~,. OF l~E ~K~ Khl~ hrll~( L,llMh~

In order to better illustrate the advantagec of the invention and its ~ nf~h~ltions to the art, several preferred hardware emb~ , of the invention will now be describe~ in detail .

O 2147~1~
- A first embodi~en~ Or the present il~vsntion provides a key cuttin~ machine sho~n generally al: 10 in }~IGS. 1-4 which c~n be used for duplic~ting the bit pattern ~oin a pre-cut master k~y onto a key 3~1ankr whether tlle master ]~ey is a single sided key ~r a dou~le sided key. A fron~ panel 12 of the r.lachine 10 has. two vertically arranged windows 14, 16 (FIGS. 3 a~d g) or rec~ivir.c the master key and ksy blanl~ respecti~ely~
~eld on the ~ont panel 12 is a red indicator light l~
with an associated push button 20 and a green indieator~light 22 with 2n afisoclated puf;h but~ on 24. Under nor~al circumstances, wh~n an operator inten~s to make a duplicate ~ ey, the green light 22 will be lit signaling that the maehine i3 ready for the ~cceptanee o~ the master key anc~ key blan]c. The key cutting ~n~chine lO i~ designed to accept eith~r single aided keys or double sided keys, although 3ince suc}l keys have ~ di:fferent con~igur~tion, diferent re~eiving apertures are prov.ided or single Jsided and double sidf3d Xey~:.
On the front panel 12 there is a rotary ~no3~ 26 positioned beneath the windows 14, 16 whieh is manually rotat~d by the operation to select the apertu~-es for double or ~in~le sided keys. Eccentric cams ~8, 30 col:~nected by a rod 32 t~IG. 9) are operated ~y the knob 26 such that as the knob 26 .i; rot~ted t~rom a f ir~t counter-clock ~risemost po~ition to a second clockwi~:emost position, an llpwardly f~cin~ portion 34 of t3ne cams -: 214~51~
2&, 30 is increasingly spaced from an axis of rotation 36 of the knob (FIG 3). A pin 38 captured in an arcuate slot ~îO provides limits of travel for the knob 26 such that the knob 26 is capable of rotating only through 180.

When the cam is in the counter-clockwisemost position, as illustrated in FIG. 3, a key receiving r-~7;nr~ 50, which has a bottom surface 52 2.U~ OL ~ed on the upper surface 34 of the cams, is permitted to drop to a lowest position. In this lowest position thè key r~~7ine S0 ~LeSe:ll-S an ~peL~ULe~ 54 in wintlow 14 for receiving a single sided master key Nl (FIGS. 3~nd~).
Also, the key receiving ~-~l7in~ 50 ~LCStll~ a second dpeLLUL~ 56 in window 16 for receiving a single sided key blank Bl. If the knob 26 i5 rotated clockwise 180-, then the entire key r-g~7ine 50 is elevated to an upper position where it ~ ~ ~ a third a~L~UL~ 58 in the window 14 for receiving a double sided master key N2 and p~t:S~ S a fourth aperture 60 in window 16 for receiving a double sided key blank (not shcrv n) .

The r-~l7~no 50 is vertically removable from the key cutting machine and has a pair of guide rails 70, 71 (FIGS. 10, 12~ on the back of a rear wall 72 thereof which are guided in a vertical channel 74 (FIG. 9) in an int~ te wall 76 in the machine 10. - -Although the r-~7inf~ 50 accepts at least 90~6 of all 19 . _ ~ ~147~1~
flat keys having a tooth pattern along one or both opposite edges, the rogi~z;n~ coula be removed and replaced by a different magazine capable of recelving other keys not accepted by the disclosed ~-~7 1 n", The knob 26 is preferably provided with a ridge 62 (FIG. g) extending diametrically across the knob which includes a pointer 64 at one end. Appropriate indicia 66, 68 are provided on the front panel 12 so that the position of the knob 26 and the pointer end 64 relative to the indicia 66, 68 will advise the operator as to which position, that is single sided or double sided, the key ~og~n~ 50 is in. Further, ~ ,L..~Liate indicia may be provided adjacent to each of the opC~nin~c~ 54, 56, 58 and 60 on the key r~ in-~ 50 which may be exposed and viewable through windows 14, 16 to further advise the ~II?eL~O~ of the positional status of the key r-gi~7in~ 50 Once the appropriate apertures have been 8~1 ect~ by rotation of the knob 26, the key machine will be ready to accept the master key and key blank. To insert the master key in the a~cLl_uL2 exposed through window 14, a clamp release lever handle 80 (FIG. 5) i~ pushed ~ &L~i-Ldly to release a ~ixture member in the form of an upper key receiving clamp 82 (PIGS. 5, 7 and 10).
The lever handle 80 is dLl ~,~.ed to a lever arm 84 which pivots about a pin 86 hor~ ti~lly secured in the ~-go~in~ 50. The arm 84 has a slot 88 therein which receives a projecting pin 90 of a 21~7~15 cam sliding bar 92. The cam sliding bar 92 has a cylindrical rear portion 94 which is ~ lin~ly received in a cylindrical passage 96 (See also FIGS. 8 and 12) such that the cylindrical portion 94 can slide forward and backward within the passage. An abutment surface 98 (FIG. 8) is provided at a forward end of a slot 100 in the wall of the cylindrical passage 96 to be engaged by the pin 90 to prevent the cylindrical portion 94 from moving too far forward in the r~-g:~in~_ The cylindrical passage 96 has a front opening 102,~and the cam sliding.bar 92 has a forwardly projecting portion 104 which extends through the opening 102 and proj ects forwardly thereof. A forward end 106 of the projecting portion 104 is uL-~d in a guide slot 108 formed between two tabs 109 in a front wall 110 of the ~-g;~ n~ 50 such that the cam sliding bar 92 may be moved ~orwardly or rearwardly, but is otherwise ~u-_l and pL~ ..Led i~rom rotating about its longitudinal axis or turning perpc~ A~- to such axis.

Formed on opp~sln~ side faces 120, 122 of the projecting pOrtion 104 are cam wedges 124, 126, 128 and 130. The cams 124, 126, 128 and 130 each comprise an open wedge shape having a forward vertex 132 and two rearwardly diverging legs 134, 136 (PIG. 7).

A jaw member 150, being an upper movable jaw, and a lower 751~
.
movable jaw member 152 are engaged.by the cams 124, 126, 128, 130 and are caused to move vertically in Le~ to horizontal movement of the cam slide bar 92. The upper movable jaw member 150 has an "h" cross-qPc~ n~l shape (FIGS. 5 and 15) with two, spaced apart downwardly PYtPn~inq legs 153, 154 c~ llle~,Led at a top by a horizontal web 156 thereby leaving a longitudinal vertical slot 158 th~.~ h_~n. A vertical leg 160 extends upwardly from lower leg 154. Legs 153, 154 are identically shaped in a longitudinal sense and have two, spaced apart, upwardly and rearwardly angled lateral slots 162, 164 (FIGS. 5 and 7) which receive and engage with the upper legs 134 of the cams 124, 126, 128, 130.

~he second, and lower movable jaw member 152 ha3 a "U"
ionAl shape (FIG. 5 and 15) having upwardly pro~ec~ing legs 166, 168 c~nnP~P~l at a bottom by a web 170 and forming a longitudinal slot 172 ther.l~ The legs 166, 168 are i~Pnt~ Ally formed and have two ~' . .lly and LeaLwaL~ly P~Pn~n~ lateral slots 174, 178 (fig. 7) wh~ch receive and engage the lower legs 136 Or the cams. The slots 158, 170 receive the forward projection 104 of the cam sliding bar.
The upper iaw member 150, along a lower edge 180, has a ly P~Pn~linq pro~ection 182 adjacent to an upwardly ~-~Pn~linq lateral slot 184 and the lower jaw member 152, along an upper edge 185, has a ~ dly P~pn~inq lateral slot 186 mating with the downwardly extending proiection 182 of the upper jaw member 150, and an upwardly F~ n~n~ projection 188 which extends into and engages the slot 184 Or the upper jaw member 150. This inteLe~ L of projections and slots allows the two movable jaw members 150, 152 to move vertically relative to one another but pL~Y~:-IL# any horizontal motion of the jaw members relative to one another.

As the lever arm 84 is moved rearwardly, its ~onn~ t i ~n to the cam sliding bar 92 through pin 90 at slot 88 causes the cam sliding bar 92 to move rearwardly in the cylindrical pa, ~;sage 96 thus drawing the cams 124, 126, 128 and 130 rearwardly. The legs 134 and 136 slide hori7~ntz~11y relative to the movable jaw members 150, 152, which jaw members abut against an end face 189 of the passage 96 at one end and against the tabs 109 at an opposite end and thus are ~L~vtzl.Led from moving hori~nt~l~y. A
bottom surrace o~ legs 134 and a top surfaoe of legs 136 cause the upper jaw member 150 to move d lly and the lower movable ~aw member 152 to move upwardly. Spaced above the upper movable jaw member 150 is an upper fixed jaw member 200 and, spaced below the lower movable jaw member 152 is a lower rixed jaw member 202.

Thus, as the lever arm 84 is moved rearwardly, the upper ~a~r the lower movable ~aw member 152 is moved away from the lower rixed ~aw member 202.

The aperture 54 in e~e front ol the r~ inc- for 21~751S
~eceiving the single sided master key Nl aligns with the space between the upper fixed jaw member 200 and upper movable jaw member 150 and the aperture 58 in the front of the r-~a~;np for receiving the master double sided key N2 aligns with the space between the lower movable jaw member 152 and the lower fixed jaw member 202. As the lever arm 84 is moved rearwardly, the sp~ nqC between the movable jaw members 150, 152 and the fixed jaw members 200, 202 increase thereby permitting a master key to be easily inserted through the selected ope~ing 54 or 58 as tc~nmin~ 7 by the position of the cam knob 26.

In the i ~ ctr~-tion of FIG. 7, the single sided key opening 54 has been s~ ct~ and the single sided master key Ml is shown as being inserted through the opening 54 between the upper movable jaw member 150 and the upper fixed jaw member 200.
R~f ~rrin~ now to FIGS. 7 and 13, as the master single sided key Ml is inserted through the opening and into the space between the jaws 150, 200, a forward edge E of the master single sided key, which, for all such keys is formed at an angle to the length of the key, engages a ~im-li7rly angled face 220 of a cylindrical plunger member 222 which is caused ~o move rearwardly against the bias Or a spring 224 into a cylindrical passage 226 in the r-g:-~inr~ The angled face 220 causes the key Nl to move toward the 71rc- 7n,.~7n~ leg 160 of the uppçr mova~le jaw member 150 50 that a flat back side F of the master single sided key Nl will be urged and positioned against the leg 160 to ensure correct 7~;15 r -positional ~ nt of the master single sided key. The master single sided key Ml will be inserted until further insertional -- v~ is no longer possible because a shoulder S on the single sided master key Ml (which all such keys have) abuts against a front face 228 of the r~ ;n~ 50 The plunger 222 includes a protruding key portion 230 which extends radially from one side of the plunger and which is received in a rectangular keyway 232 formed in the passage 226 (PIG. 12). This L)~:V'~ 5 rotation of the plunger 222 wit,h~in the passage 226. When rearward p~esDuL~ against the handle 80 of the l~ver arm 84 i8 released, the lQver arm 84 is urged fo~wardly by the; n~ pn~e of a spring 240 (FIG. 5) which engages at a first end 242 with the lever arm 84 and at a second end 244 with an arm 246 projecting horizontally from a vertical post 248 formed on a top of the 7~ ne 50. The post 248 and spring 240 are normally enclosed beneath a cover 250 held in place by a~L~.~Liate fastening members 252 such as U .~aded screws. The lever arm 84 extends upwardly through an opening 254 in the cover.

As the lever arm 84 moves forwardly, a forward edge 256 thereof engages against a forward end 258 of the opening 254 which acts as a stop. In this position, the slider bar g2 will be moved forwardly causing the cams 124, 126 to slide forwardly relative to thQ movable jaw members 150, 152, thereby urging the upper j~ =e:ber lS0 Lpwar~lly aDd the lower mo~ble ~ ber ~ ~14~51~
.
152 downwardly. In this manner, the upper movable jaw member 150 will clamp the master single sided key Ml firmly between the upper movable jaw member 150 and the upper fixed jaw member 200.
Thus, the master single sided key Ml will be firmly clamped in place against the upwardly ~ n~in~ leg 160 of the upper jaw member 150 and between the upper movable jaw member 150 and the upper fixed jaw member 200 and will be held in such clamped position by the bias of spring 240.

An identical operation occurs during insertion of ,~he single sided key blank Bl into opening 56 which will be eYposed through window 16. For insertion of such key blank, a second lever knob 250 c~ -1 to a second lever arm 252 is moved rearw-ardly to cause an identical upper jaw member 254 and lower jaw member 256 to move apart from an upper fixed jaw member, which i8 the same ~ L~ 1L~1 unit as the lower fixed jaw member 202 ~ d l~l~aIGfLLG is also referred to with reference numeral 202) and a lower fixed ~aw member 258 respectively. Thus, the single sided key blank Bl can be inserted into the opening 56 to lG~aLwc~Ldly d~splace an ~ n~ y shaped plunger 260 which causes the single sided key blank Bl to be held against an upper leg o~ the upper movable jaw member 254 in precise ;~ with the single sided master key Ml clamped above it.

.
Release of the second lever 250 causes forward VG
o~ the lever under bias of a spring 262 mounted in an identical ~ 2147~1~
.
aLL~ .t to spring 240, thus resulting in a firm clamping of the single sided key blank Bl between the upper movable jaw member 254 and the upper fixed jaw 202.

Nith both the ma6ter single sided key Ml and the single sided blank Bl now fully inserted and clamped in place, the cutting operation may begin. Thi8 ig . ,1 i F:hf~d by pressing the actuator button 24 adjacent to the green light 22 on the front panel 12 of the key cutting machine 10.

Nhen the button 24 is pressed, switches are latched closed which energize power means in the form of two separate cutter motors 300, 302 as well as a c~ e motor 304 (FIGS. 1 and 6). FIG. 6 illu~LL~tes the assembly of the cutter motors 300, 302 onto cutter blocks 306, 308.

Cutter motor 300 in~ a drive shaft 310 projecting from a ~orward face thereof which receives a drive gear 312 secured in place by a pin 314. The drive shaft 310 and gear 312 project through an opening 316 in a back plate 320 for cutter block 306 and the cutter motor 300 is secured to the back plate 320 by a plurality of a~ v~ iate r. LQI~ (not shown) which extend through OpQnin~ 322 in the back plate 320 and into op~nin~c 324 in the front face of the motor 300.

A cutter wheel 330 is carried on a chaft 332 and is keyed ~ 2~4751~
against rotation by means of a pin 334 engaqing in a.key way 336 in a central opening 338 receiving the shaf i: 332 . A C-ring 340 snaps into place in a groove 342 on the shaft to lock the cutter wheel 330 axially in place on the shaft 332. Thus, the wheel 330 can easily be removed and replaced from the front of the machine upon removal of the C-ring 340. Removal and repl A~ -L is facilitated by making at least an upper portion of the front panel 12 removable to expose the wheels 330, 360. The shaft 332 is inserted into a bearing 343 which is held in a front opening 344 in the cutter block 306 and the shaft 332 receives a g,ear wheel 346 which is keyed to the shaft 332 for co-rotation therewith. me shaft extends through a rear-bearing 348 and a washer 350 i8 ill~ r,~ Ct~l between the gear wheel 346 and a snap ring 352 which 6naps into a groove 354 on the shaft to hold the gear wheel 346 in a fiYed axial p~siti~n on the shart 332. The teeth of the gear 312 mesh with the teeth of gear 346 such that rotation of the drive shaft 310 of cutter motor 300 causes rotation of the cutter wheel 330. The use of the two gears 312, 346 causes a rP~ ion in the speed o~ rotation of the cutting wheel 330 to assure an er~ective cutting of the keys. The second cutter motor 302 and a second cutter wheel 360 are mounted on cutter block 308 ~t nl-~cAl ly to the description of the first cutter motor 300 and cutter motor 330.

me cutter block 306 includes tracing means in the form of a movable tracing or fnl 1 ._, arm 361 which is slidably . ~. 21~7~1~
.
carried in a Llot 362 in a top of the block 306. A threaded fastener 364 and washer 366 engage over a top of the movable follower arm 361 and engage into a threaded aperture 368 in the block 306 to firmly clamp the arm 361 in a selected position in the slot 362. A second threaded fastener 370 with a washer 372 secured thereto is threadingly received in an aperture 374 in the block and the washer 372 is ~ UL~ d in a slot 376 in the follower arm 361 such that rotation of the fastener 370 will cause the fastener to move axially drawing the follower arm 361 with it. f -The fnl 1 ~ _r arm 361 has a front face 380 which is in precise longitudinal Al i 3 ' with a front face 382 of the cutting wheel 330. The follower arm 361 has an angled back face 384 at one end which has a slope i~ nt~ l to an angled face 386 of the cutter wheel 330. The follower arm 361 can be laterally moved into precige vertical ~1i,3 with the cutter wheel 330 80 that a leftmost edge or finger 388 i8 in vertical ~1 it with a leftmost point 390 on the cutting wheel. As seen in FIG.
13, the follower arm 361 engages a bit edge B of the single sided master key Ml. The leftmost edge or finger 388 is used to trace the pattern or configuration of the bit side B of the key and to cause the cutting wheel 330 to duplicate the pattern onto the single sided key blank Bl which is clamped in preci8e ;.li,3 below the single sided master key Ml. In this manner, precise duplication of the bit pattern is achieved.

~147~15 The second cutter block 308 is provided with an identical tracing or follower arm 400 with a finger 401 which can be laterally adjusted and secured in place in a manner identical to the first described tracing arm 360.

The cutter blocks 306, 308 are in~rr~nrl~ntly mounted on a carriage 402 and are mounted to be in-l~r~n~r~ntly laterally and linearly movable relative to the carriage 402. The cutting block 306 (and the same is true for block 308) has a pair of gui,de rods 404, 406 secured thereto which extend between lateral side walls 408 and 410 of the guide block in a Le:ce_sed space 412 (FIG. 2).
The guide rods are received in linear bearings 413 ~ a~Lu~d in bores 414, 416 of the carriage 402 80 that the cutting block 306 is lntor~lly and linearly ~:tlitls-hlo on the Arri~e The cutting blocks 306 and 308 are normally biased towards one another by a i~irst, soft spring 420 (FIG. 1) L;a~LUL~:d within the blocks 306, 308 by a threadingly adjustable stop 422 by which the inward biasing pL~ uLe: can be selectively adjusted.
The ~L~5~u~t: of this soft spring 420 i8 not so great as to prevent insertion of the master or blank keys by causing the tracing arms 361 and 400 and the cutting wheels 330, 360 to close off the key receiving space between the jaws, however the spring >r~UL~ is great enough to cause the cutting blocks 306 and 308 to move toward each other once the keys are fully inserted 80 14~15 that the tracing arms 361 and 400 are in engagement with the keys or upper movable j aw leg as E~ r~t~

The carriage 402 is movable itself in a linear longitudinal direction and is carried on guide rods 430, 432 (FIG. 6) which ride in linear bearings 434, 436, 438 and 440 (not seen). The guide rods 430, 432 are secured at a forward end ir~
the ~ront panel 12 of the hous~ing and at a rear end in the int~ te wall 76.

~r The carriage motor 304 has a drive shaft 444 which protrudes through an opening 446 in a support bracket 448 and is rotatingly received in a collar 450. A pin 452 extends through a 90- slot 454 in the collar to provide a 90- loss motion c~nn~c~1-n between the drive shaft 444 and the collar 450. A
drive screw 456 has a i~irst end 458 which is rotatingly received in the collar 450 and a pin 460 extends through the end 458 of the drive screw 456 and through a 90- slot 462 in the collar to provide a second 90- loss motion c~nn~cf~-~n between the collar 450 and the drive screw 456. A second end 464 of the drive screw is Ll,L~:aded and is received in a l,I,L~aded opening 466 of a nut 467, in turn Ll~e aded into a back wall 468 of the qArri~e 402 at a U,Lc:aded opening 470.

As the carriage motor 304 operates the drive shaft 444 in a first direction of rotation, and after the two 90- loss motion connections have been ~hsorhF~d, the carriage is causea to move rearwardly through the threaded c~nn~c1~ n between the drive screw 456 and the threaded opening 466. When the motor 304 i~
L. v~:,ed, again there is ~irst 180- o~ loss motion of the drive shaft 444 relative to the drive screw 456 and then the carriage is caused to move in a forward direction.

Thus, when the start button 24 is pres6ed, the cutter moto~s 300, 302 are energized causing the cutting wheels 330 and 360 to immediately begin rotating. The tracing arms 361, ,400 hold the cutting wheels at a lateral location i~onticAl to the edge of the master key. The carriage motor 304 is also energized and begins to rotate, and after 180' of rotation of its drive shaft, the carriage begins to move rearwardly. q~he 180 of loss motion gives the cutting wheels 5 t'1'1~ nt time to reach full cutting speed so that the cutting wheels are at full speed before the tracing arms 361, 400 are moved longi~ in~l ly toward the cut portion o~ the key. Also, the tracing arms 361, 400 are pres~:ed lightly towards each otber assuring contact Or the fingers 388, 401 with the outline of the key to be traced.

As the carriage is moved rearwardly il.~;L_~sed inward ~Le:a~ L~ is applied to the cutting blocks 306, 308. As seen in FIGS. 1 and 6, this is n~ h~ by means of a roller 480 which is carried on a pair of spaced arms 482, 484 by means of a pin 486, the arms being carried on a bracket 488 by means oE a ~ 2147Sl~
pin 490 so that the arms are free to rotate relative to the bracket 488. A strong spring 492 which i5 carried in a bore 494 of the cutting block 306, protrudes from the cutting block 306 and engages.the arms 482, 484 an~d presses the roller 480 outwardly. The ~5::~UL~: of the spring 492 can be adjusted by means of a threaded nut 495 carried in the cutting block 306.
The roller 480, when the cutting block 306 is in the position closest to the front panel 12 of the key cutting machine 10, is not ~nnt~ct~cl by any other part of the machine and ther~fore does not provide a strong inwardly biasing force. However, upo~
rearward - ~ of the carriage 4~2, the roller 480 engages against a slanted face 496 of a rod 498 which extends between the front panel wall 12 and the i-~ te wall 76. A pocket 500 which Inr lllrlr s the sloped face 496 i8 provided adjacent the roller 480 in the forwardmost or home pnctirln of the carriage 402 so that the strong spring 492 is inr~1~fer~tive in the home position. However, as the c~rri;~Je moves rearwardly, the roller 480 engage3 the slope face 496 and causes the strong spring 492 to more forcefully bias the cutting block 306 toward the c~nt~rl Inr~ of the key cutting ~~~hinr~, This assures that during the cutting operation, sl~ff1cl~-~nt force i8 applied between the tracing arm 3 60 and the key to assure accurate tracing of the teeth on the key. As the carriage 402 cnntin~ rearwardly, the roller 480 rolls on the outer surface o~ the rod 498 to provide the strong inward bias on the cutting block 306. Cutting block 308 ha~ an ~ t~l ;m/ard bia~ u~ L It ~b=ld be r~ted that in ~IG. 1, it does not appear that the rollers 480 would engage the rods 498 to any great degree, but this is only because FIG. 1 illustrates the key cutting machine 10 with the magazine 50 removed. ~hen the r~ ino is inserted, the blocks 306, 308 will.be caused to move laterally thereby moving the rollers 480 well into the pockets 500 and a6suring . e .sion of the strong spring 492 when the carriage moves rearwardly.

As the carriage 402 moves rearwardly, the tracing arm 360 rides along the bit edge B of the single sided master key ~1 and causes the cutting wheel 330 to cut an illontit-;~l pattern in the single sided key blank Bl. The tracing arm 400 rides along an outside surface of thc upper leg i60 of the uppcr movable jaw member 150 to hold the cutting wheel 360 away from the flat side o~ the key blank and the upper leg of the upper movable jaw 254.
The carriage 402 continues to move rearwardly and as it does, a rear edge 502 (FIG. 13) of the cutting block 308 engages a tab 504 on the plunger 222 to move the plunger 222 longitl~Ain~lly and ~eaLWC~L Ily away from the key. This ~LeV~..Lf~ the cutting wheels 330, 360 from ~ngagin~ the lower plunger 260.

When the carriage 402 reacheg a pr~ t~rmin~cl ~e~lLwcll~' L po51tic~n, a rear face 506 of the carriage engages an a_Lu~.Lu- button 508 o~ a microswitch 51Q carried on a support bracket 511 which causes the cutting wheel motors 300, 302 to become deenergized and causes the carriage motor 304 to be 2147.~1~
reversed. Wh~n this occur~, the cutting ~,~heel~ 330, 360 stop ~otating and the aarriage ~egins to ~ve forwardly to~rard the home position. A~ thi~ pOillt~ tne rel Li/~ht ~3 on th~e front panel 12 i8 illum}nated sigllaling the opi3~-ator that t~he lcsys may be removed. The lever arms 84 and 252 ma~, be pressed rearwardly to release the clamping jaw:: from engilgement ~lith the keys, and the for~ard mo~ement of the tracing aJ~ and non-rota~ing cutting Wheels will urge the keys f~rwardly out o~ tne openings 54, 56 in the front panel. The red light will contlnue to bQ ill~minated until the carriage 402 arri-re~ a~ the fu~1 forward o~ ho~e poqition at which time a se~ond micros~itch 512 c~rri~d on the carrlage will ~e actuated by contact ~ith a 3tationary stop !~13 which causes the carri~ge ~otor 304 to beaome deenergized and c~uses the green llqht 22 to become i~luminated.

Pressing the button 20 next to the red light 18 anytime during the operation of the machine w~ll have the ~am~ effect as ~ctuation of microswitch 5~0, that is, the cuttlng wheel motors 300, 302 will be deenergize;~, stoppin~ the rot:ation of the cutting wheels 330, 360 and causing the carriage motor 304 to reverse, sending the carria~e back to the home po~;ition. If power to the machine i5 removed anytill~e during the cu~ting operation, upon resumption of power to the machine, no motor~;
will be energized and only the red indic~tor light 18 will be illuminated. The button 20 next t~ the red illumin~tor light must then be pressed which 7~ill caus~ th~ carriag~ motor 304 to -~ 2~7Sl~
operate in a reverse direction sending the carriage back to the home position.

A removable tray 520 is provided which is received beneath the position of the cutting wheels 330, 360 and which receives the ~r;n~lin~s from the cutting wheels. The tray can be laterally removed for flispqs~l of the cuttings and laterally replaced permitting easy and complete collection of the cuttings.

If a double-sided master key M2 (FIG. 14) is selec~ed for duplication, then the operator would rotate knob 26 so that the pointer 64 points to the indicia 68 for double sided keys. This will cause the entire r~ inP 50 to elevate P~osin~ opPnin~s 58, 60 through 14, 16 respectively. Double-sided master keys M2 are cqnf~ ed ~ t differently than single-sided keys in that there i8 no flat edge against which the key can be pressed and longit~ in~lly ~ npd~ Kowever, all double sided keys have a pointed forward end P and thus a plunger 600 to be engaged by the double sided master key M2 has a pair of slanted forward edges 602, 604 which _1 ~ the pointed end P of the double sided key. This ensures a CpntD~-i n~ of the key tip in the space between the lower clamping jaw member 152 and the lower stationary jaw member 202. The double sided master key MZ is inserted until the plunger 600, which has a rearwardly P~Pn~i portion 630, and which is forwardly biased by a spring 632 bottoms out by the Lealw<~ dly extending portion 630 engaging a 2147~1~
r cover ~trip 634 at the rear o~ the r,~ in~- 50. By such an ~rrangement, it will be ensured that ~sn id~ntical length of a double sided master key ~2 ~nd a doubl8 aided key blan~c wil 1 be presented f~r traclng an~ cutting respectively. 'rhis is impo~tant since double sided keys do not have shoulders like shoulder S on the single si~ed master Itey Ml.

To ensure a centerin~ of the double slded shank of the key; the opening 58 includes a pair o~ inwardly biase~ guides ~06, 608 (FIGS. 5 and 11) wtllch ea~h llave a gear wheel 6~, 612 secured therebelow to the front wall :~L10 of the magazine 50 ~y pins 614, 616. ~he gear wheels 610, ~12 ride on a gear racks 618, 619 re3pectively, on each guide ~06, ~8 which a~3sure~
identical rotation o~ the geAr whe41~ 610r' G12 and thus ensures id~ntical lat~ral movement s~ the guides 60~ ~0~. The guides 60~, 608 are normally biase~ inwar~ly by springs ~20, ~22 such that the guides will engage the ed~es of the }:ey shan~c an~, ~ue to the identical lateral r.-v. - 1~ ~f ~he guides 606, ~0~, it is ~ssured th~t the shank wi}l rem~in cel~tered as well as the tip, thus provi*ing an accurate centering and longitudina3 alignment o~ the double sided key. When the lever arms are re}eased, an identical clamping action o curs as we~s described above with respect to single sided. keys and thus the double sided keys ~bcth master and blank~ will be ascurat~ly maintained in place in the mag~zine 50 .

-- 2~7~1~
_ In all othar re~pects, the op,~ration of the k~y cuttinS' machine is identical for double gided keys a~ was de~:cribed for single sided keys with the exc~ept~on I-hat the tracing arm 400 now does engage against an edge of the key and th~ls doe3 ~ause the cutting wheel 36~ to in aci~ cut the ~cey ~,lan}~ positi~Dned in the lower; aw set.

Thu~ it is seen that the pres~nt invention pr~vides a method and apparatus f4r automatically cutting keys td~ich comprises a pair of cuttin~T wheels ea~h h~vln~l a cutt~ng ,edge and with at lea~t one of tne wheel3 being mounted for movement towards and away from the other. Biasing means are p~ovided for bl~sing the cutting edges o~ the wheels towards ons another.
~eans are provided for fixing both a key blank and a ~cey tc be duplicated and edge tracing me~ns ~rQ provided to engage s~id key to be duplicated whiah effects movemellt o~ at least one of said cutting wheels towards and away from ~he other in coneormity with an ed~e con~iguration ~r the key to b~ duplicated. A power means having an actuation me~ns move5 thf~ key blank rolative to thP
wheels ~nd moves the key to be duplicated ~elatlve to the tracin~
means .

FIGS. 16, 17 and l9 generally illu3trate the key cutting machine o e the present invention . In order to more readily ~ppreciate the various ~eatures an~ fl~nations o~ thi~3 key cutting machine, the various type~ of kQys which can be duplicated 4n 3~

-~ 2~7~1~
, thi~ key cutting machine will fir~t b~ de~crlhed and identified in connection with FIC:S. 31-35.

FIG. 37 and sec~ion~l view FI~. 3~A illustrat~ a conventional single si~ed Xey 70~ haY~ng a bit:ted surEace 110, an upper surfacs 712, a 14wer 3urface 71~, a tip 716, a ~houlder 718, a linear root æurface 720 an~ a 3han~c 72~ e~erence num'oer 724 indicates that fir~t bitted surface 710 of key 703 includes a series of cut3 extending laterally hetween a ~irst lateral position 7~6 which approaches most closely to ke~ roo~ 7~0 and a second lat~reil position 728 which is ~ate~^all~ di~place~ the greAtest diætance away from key roc~t 720.

.

FIG~. 32 and 33 illustrate a conventional two-sided key 730 which includes most of the same elemelltæ of tho~e described ~bov~ in connection with singlQ sided key 708. Two s.ided key 730 inclu~es a key centerline 732, a first bitted s~rface 73~ and a second bitted sur~ace 736. Double-sided key ~30 does not include a root. Double side 3cey 730 includes cutæ extending lat~r~lly bet~een a first lateral position located in proxin~lty to the key centerline 732 and ~ æecond lateral po3ition further displaced from the key centQrline on both the fir~t bitted sur~ce 734 and second bitted surface 736. Double-si~ed ~cey ~30 illu~trated in FIG. 32 includes paired shoulders 71~ asl well as a shank 722.

FIG5. 34 and 3~ illustrate another form o~ double-sided 21~751~
key 738 which also 1nrl~ s a key centerline 732. As shown in FIG. 34, double-sided key 738 includes a key shank 722 but does not include any shoulder surfaces.

To ~ ri he the overall operation of the key cutting machine of the present invention including all of its operational elements, the t>l.LU~ ULe and operation of the key cutting machine will initially be described in connection with the ~l~lrl i~atic~n Of a two-sided master key onto a two-sided key blank.

As ill~DI_ ~Led in FIG. 16, the key cutting machine i n~ a vertically oriented central plane of l,y y which precisely bisects the machine between first cutting wheel 740 and second cutting wheêl 742. The key cutting machine also inr~
a l~nrJit~ n~l axis which e~ es~ a linear h~ri7~nt~l axis line lying in the vertiQlly oriented plane of Dy ' y. The longitudinal axis is parallel to the line ~ n~te~ by reference number 744 in FIG. 16. The key cutting machine also inr~ s a lateral axis which passes through cutting wheels 740 and 742 and which is parallel to the dotted line ~lo~ n;~ted by reference number 746 .

Pr~fr rring now to FIGS. 16, 17, lgA, 22A and 22B, the key cutting machine of the present invention in~ a base 74~, a first cutter head 750 and a second cutter head 752. First cutter head 750 includes a i~irst key follower 754 positioned at a first .
21~7~1~
- elevation and a spaced apart first cutting wheel 756 positioned , at a second elevation.

Second cutter head 752 includes a second key follower 756 positioned at the first elevation and a spaced apart second cutting wheel 742 positioned at the second elevation.

Drive means i8 I coupled to the first and second cuter heads for rotating first cutting wheel 740 in a first direction and for rotating second cutting wheel 742 in a second direc~tion opposite to the first direction as shown by the arrows in FIG.
22. In the pr~f~orrin~ ir-nt of the invention, the drive means takes the form of a first ~lecf~ic! notor 758 (see FIG. l9A) and a second ~ cfric motor 760 (see FIG. 21). Motors 758 and 760 typically take the form of DC energized po~ magnet motors having an llnlo:ulcd operating 6peed of about 4000 RPN.
Such motors are commercially available from Colman Motor Products, Inc. of Darlington, wi~n~ n~2in and include a gear speed r-~-n~i-n unit designated by reference number 762 which provides the desired 2200 RPM cutter wheel speed. This ~otor/gear r~ nti~ n assembly is ~ ~ign~ted as Colman Motor Products, Inc.
Part No. D44-2401-1.

The key cutting machine of the present invention also includes first linear lliF;rl~ L means which is illustrated in FIGS. l9A, 21 and 22 and is designated by reference nu~ber 768.

.

~ 2147~15 `:

_~irst linear displacernent means in th4 ~r~ferred ~ml~odiment of th~ invention takes the fo~rn of a linl3ar }~earing ~heana including a ~irst linear bearing 770 e~nd a ~ecol-~d l:~near oearin-~ 772.
First linear bearing 770 is coupled b~-twe~n belse 74~ ~nd the lower surface of first cutt~r head 7~t) wh~ile E:econd linear bearing 772 i8 coupled betw~en bas~ 7 ~8 a~d t~e lower surface of second cutter he~d 7S2. As is mos~ y ill~ strated in FIG. 21, each linear bearln~ lnoludes a fixed l~ear;.n~ element 774, a laterally displaceable bear~ng ele~nent 77~i and a spring-actuated b~asing device 778 whi~h operates ~n each linear bearing ~element to bi~s the first ana secon~ cutter heaaS toward the centerline of the key cuttlng mac~ine ~g well a& the centerline~ o~ maSter key 764 and key blanX 766.

First linear displacement means 768 is coupled to basc 748, first cutter head 750 and second cutter head 752 to simult~neously latera~ly displace first ke.y f~llower 754 and first cutter wheel 740 toward and ~way from the fLrst bitted ~urfaces of the two sided ~ste~ key -~64 an~ the two ~ided Xey l~lank 7~6. ~I~S. 19 and 38 illustrste the relative po3ition3 of master key 764 ~nd Xey bl~nk 765 r~lative to the overall elements of the key cutting machine. I~he str~ctur~ and function of the cacsette key aliS~nment ~ixt~re which recelves, align~ ~nd longitudinally displaces ma~ter key 7~i4 and k~y blank 766 will be described below.

2i47~1~
As illustrated in the drawings, base 748 of the key cutting machine is horizontally oriented as are the bearing surfaces of first linear bearing 770 and second linear bearing 772. mis specific configuration of the linear bearings of the present invention enables first and second cutter heads 750 and 752 to be laterally ~ p1;~r~ in a horizontal plane such that gravitational forces do not alter the effect of or force exerte`d on the key6 by the spring biasing devices 778. In other words, the l-ateral biasing forces dxerted on cutting heads 750 and 752 toward the machine centerline are controlled exclusively by;
biasing springs 778. me lateral biasing forces (on the order of about fourteen ounces to as low as about eight ounces) exerted on cutter heads 750 and 752 are Ll.er.~Lor~ both relatively cnnc~t;~nt and ~ _ 1 r~t~1 y i n~r-~n~nt o~ gravitational forces .

Due to the , ~.~ively weak forces exerted by the spring biasing devices 778 on cutter head 750 and 752, tilting the base 748 of the key cutting machine po~ n~ as shown in FIG. 22 clockwise to the right to an angle on the order of thirty to ~orty-five degrees would cause yL~vl~ ional forces to readily ~v~L~ the co~nt~ rt1n~ spring biasing force~ on cutter head 752 ~nd would cause that cutter head to drop off to the right and out of contact with keys 764 and 766. me opposite effect would occur with respect to cutter head 752 where gravitational forces would add to and :,..1~,...l 1;~11y increase the lateral biasing forces exerted on keys 764 and 766 by the spring biasing device ~ 21~7515 - 778.
-It is thus important to the proper operation of thepresent invention that the base 748 be oriented into a subst~ntiAlly horizontal position such that the controlled inward bia6ing forces exerted by biasing springs 778 operate subst~nt~lAl ly in(lf~p/~n~F~ntly of gravitational forces.

- In order to ensure faithful r~L-,du~:Lion of the bitted surfaces of master key 764 onto key blank 766, it is important that first linear ,lisrlAr ' means 768 provide for exclusively linear lateral axis .1;F:P1:~I ' of cutter head 750 and 752 relative to master key 764 and key blank 766. It is therefore ~ _ L~u.~ to avoid utilizing a lateral ~ rlA( ' device which provides for curved or non-linear lateral ~ rl A~ ' of the cutter heads relative to the keys.

The first linear ~ r~ means 768 ~rihf~ above enables first cutter head 750 to lAt~rAlly follow and ~ rlir~A~t~
the fist bitted surface of master key 764 onto the first bitted surface of key blank 766 and enables cutter head 752 to lat~rAl ly and follow and duplicate the second bitted surface of master key 764 onto the second bitted surface of key blank 766.

A unique int~:r~ J-~hle cassette system for a~ompli~l~ing th~ key positio~ and ,.1 i~ L f lnr~i~n~ of the 7 i l S
present invention will now be described in detail.

The key cutting machine Of the present invention includes a cAc~ette-receiving ~peL~uL~ 780 illustrated in FIG. 16 for receiving a CAccettr~ key Al i,3 L fixture 782. FIG. 17 illustrates the , ~ key Al i'j -- L fixture 782 after it has been installed in the key cutting ~~~hine~ The function and operation of the cAC~ette key A~ L fixture 782 of the present invention will first be described in cnnnPr~inn with a rAc5et~e for Al iqnin~ a single-sided key as shown in FIG. 31 and will D~ 5~ 1y be ~c~arrihed in cr nnPctirn with a c~csette of a different design for ~ nin~ a two-sided key as shown in FIG.
32 .

., _ As illUDLLe.ted in FIG. 16, the general structure of rAcset~ 782 i8 the same for both the single-sided and double-sided key Arrl ic~innC. As ill~DLL.lLed in FIGS. 24, 25 and 26, each ~5~lr~ 782 inr~ a first key Alf~ ' device 794 for receiving and Aliqnin~ master key 764 at a first elevation and a second key Al i,; ' device 786 for receiving and ~ nin7 a key blank 766 at a second elevation. The DLL~ULULC and operation of each o~ the ma6ter key and key blank key Alf~3 ' deviceD is essentially identical. The DLL~-:LU-~ and fllnrfirn of the key Alf3 ' device will LL~L~rv-= be ~Yr~lAin~ only in ç~nn~ctir~n with the second key Al il; ' device 786.

7 - ~ . 2 1 ~
-Rey A~ t device 786 includes an upper clamping surface 788 and a lower clamping surface 790. An actuator arm 792 can be displaced into a first or locked position as illustrated in FIGS. 24 and 26A where upper clamping surface 788 and lower clamping surface 790 move to a closed position to engage the upper and lower surfaces of master key 764 or key blank 766 to ~ointPin the master key or key blank in a fixed lateral position with a horizontal orientation. In FIG. 36, the rectangular dotted line area desi~nated by reference number 774 illustrates the area on which the clamping ~UL Laces operate to maintain proper ~ ; ' of the master key and key blank.

An actuator arm 792 may be moved into a second or open position as illustrated in FIG. 26B. The camming action between upper Ql: _~'n~ surface 788 and lower r.l: _in~ surface 790 caused by the inrl in~od male grooves in lower rli _ ing surface 790 and the mated female grooves 798 in upper rl; _ in~ surface 788 as best illustrated in FIG. 25 convert the longitudinal ~l;cpli~ L~, of the upper and lower Ql; _ in~ ~uLr~ =S caused by actuator arm 792 into vertically oriented opening and closing .c ' ~ of the Ql i _ ;n~ surfaces thereby causing the clamping suri~aces to move between an open position for receiving a master key or key blank and a closed position for Ql; _ ng the key into a fixed lateral position with a horizontal orientation.

As illustrated in FIGS_ 16 and l9A, the vertically -` ~ 214~51~
oriented, front surface of each cassette includes a rectangular aperture 810 for receiving a master key and a similar aperture 812 for receiving the key blank. This particular vertical relationship with the master key located above the key blank is completely optional in that the key cutting machine of the present invention could be readily adapted to follow a master key positioned below a key blank.

The single sided cassette also includes a root ;~l il~ l surface which will now be described in ~onnP~ n with FIGS,. 24, 27, 29, 40, 41, 48, 49A and 49B. Root :.1 i, ~ surface 814 is laterally offset to the left side of ~1 , in~J surfaces 788 and ~90 and receives the linear root surface 720 of either a master key or key blank. Root i~l;; ' surface 814 inrlllr~r~ an n1-~lly linear 5urface which is oriented p:~r~ to the longitudinal axis of the key cutting r~^^.hinF., Root Al i,;
surface 814 i ncl-lrir~: an upper surface whic_ extends above lower ~; " inrJ surface 790. As shown in the drawings, root ~
surface 814 extends along ~ L~ ially the entire length of the key root after key blank 766 has been fully seated into ~R~ett~
782 as ill~L~l~ed in FIGS. 41 and 48.

The key i~l i,; ' device 784 also inr ll-r~r,~R tip ;-l i5 means which in the preferred ~"~ho~ of the invention takes the form of a tip ~ plunger 816. Since single-sided keys always possess a linear root surface 720 and a bevelled tip, the en~age~ent end o~ tip al~gn:a~ent plun~cr 816 ~c)r ~ingl~3-sided key will a~ ys ~ave be~elled elld s~rface 818 as ~llustrated in FIGS.
29, 40, 41, 48 2nd 49. The lndente~ r f~r~e~l end su:rface 82~
for tip alignment plunger 8:L6 as illu~itrated in FIGS. 27 ~nd 28 is used to pro~ride compatibility with do~ble-si~ed ke~s which la~k a l inear root sur~ace .

As illustrated in F}:G. 27, th~s cy~.indrical ~nid section o:E
pl~lnger 81~ includes a biasing spring 8~2. T~Le fir3t end 824 of ~pring 822 enqages and oper~tes ag~inst a fixad surfa-~e w~thin the rear of cassette 8~2 a3 illu3trat~d ill FI~'.. 24. ~he second en~ 826 of spring 822 abutF: and op~rates against a la-~ger diameter 3ection of plunger 816 a~ illustrated in FI~;. 27.

As illustrate~ in ~rGS. 24 an~l 4gB, b~asing spring 822 maintains tip alignment plunger 816 flllly extsnded along the longitudin~l axls of the ca~sette ~o ~ locati~n near ]cey entry ApertUre 81~.

FIG. 49B show3 the ~:~peratl~n ~f tip al.ignment plunger 816 ~8 a key initially enters c-~ssette 7g2. ~IG. 4gA 3hows that key blanX 766 has ~een fully lnserted into cassett:e 782 ul~til shoulder 718 engages an~ stc~ps against. thq~ outer perip~ery of cutting wheel 742.

Because an ~ rained operator of a ~cey cuttin~ macbine 214~Sl~ `
might insert a key into ~ c.cette 782 with a ~cjgnificAnt lateral misalignment as illustrated in FIGS. 40 and 49A, the key cutting machine of the present invention includes lateral A~ L means to eliminate such lateral misalignment.
one ~ of the invention as illustrated in FIGS.
40, 41, 42, 43, 48 and 49, operates on the bitted surface of a `
single-sidea key to laterally align the key. One ~L~L~ -ly uniclue aspect of the lateral ~ system of the present invention is that it is designated to operate on a single-s~ided key at a time after the key has been firmly clamped within e 782 by operation of actuator arm 792 into the closed or clamped position. As illustrated in FIG. 24, ~ tul arm 792 is ~-~n~ n~i in the closed or Ali _~ng position by a biasing spring 828. The tension force provided by thi~ spring is d~ci~ n~ to impose a vertical ~l , in~ force on the upper and lower sl~rfA~ c of the single-sided key of on the order of about f ive pounds ~
The area of ~ of the upper and lower rli _ inj s,~LLa~ s 788 and 790 on the single-sided key is ~ i,ed in FIG. 36.
The lAt~rAlly m;cs~l~gn~cl keys 1111_.1.AteCI in FIGS. 40 and 49A are therefore ~=in~s~in~d or "lockedn into a laterally ml~ nF~cl position by ~LvA~uately twenty pounds of vertically oriented --15 _ 'n7 forces.
-The lateral Al i 3 means of the present invention is i~lustrated in FI~. 47 and sho~ls th t maste~ key 764 is engag_ ~` 2147515 at a first position ~;CP1A~-~(1 along the length of the key at a location away from the key tip. As a result of the lever action created between the tip of the key which is maintained in a fixed position by tip ~; ' plunger 816, the exertion of a late~al force of approximately five pounds by an operator on key set button 830 laterally ~icrli~r~c key set plunger 832 causing arm 834 to engage and ~i Crl ~e the adjacent, vertically oriented surface 836 of cutter head 752. The resulting inward lateral displ AI ' of cutter head 752 forces key follower 756 against the bitted surface of master key 764 at a longitudinal location aligned with Rhr ~ Pr 720 of the key. Exertion of a comparatively nominal lateral force by the v~Latvl on button 830 readily ~,vt~ the vertical ~ in~ forces of cl: in~J
surfaces 788 and 790 and permits the master key 764 to pivot about its tip and to be laterally aligned with root ~ ,3 surface 814.

SimultAn~ol~c]y with the lateral illi,, ' of master key 764, the lateral ~licr~ ' of cutting wheel 742 against the bitted surface of key blank 766 permits the cutter wheel to laterally IqiCrli~re key blank 766 fully against root i li~; ' surface 814. This lateral r~ ' of key blank 766 is shown occurring between FIGS. 40 and 49A and FIG5. 41 and 48.

By simul~i~n~ollcly ~ n~n~ the root surfaces of master key 764 and key blank 766, the root surfaces o~ these two keys 5~

-- 214~
are simultAnP~ cly aligned with each other, thereby Al iqnin~ the key blank precisely with respect to the master key.

FIGS. 42 and 43 show yet another partially cutaway view from the front of the operation of the lateral ~ ' means of the present invention. FIG. 42 shows that key blank 766 is laterally mi F:Al i~nPd to the right. FIG. 43 illustrates the manner in which the operation of key set plunger 830 causes the pPr~ r of cutting wheel 742 to engage the right hand surface of key blank 766 and laterally reposition it to the left so that it abuts against the root A~ ' surface.

A completely different type of key ~ device must be provided for a double-sided key since all double-sided keys lack a linear root surface which served a8 the lateral Al i or indexing surface for a single-sided key. For double-sided keys, a more complex and ,,u~ ;A11Y different key ~li._ device i8 provided to achieve ~ ; of the master key relative to the key blank ag well ag A1 i,; ' of both keys relative to the key A1 i ~ t device itself.

RPff rrin7 now to FIGS. 30A, 30B, 37 and 50, a key Ali~; ' device capable of Al;qnin~ a two 6ided master key and key blank i n~ a longitudinal axis and a lateral axis rAhle to the related axes described in crnnpction with FIG.
16. 'rhe key ~ device laterally aligns a first key or 2147~1S
master key relative to a first defined, fixed centerline such as centerline 838 illustrated in FIGS. 30A and 30B. Centerline 838 is essentially defined as representing the midpoint of key aperture 810 when in the closed position as illustrated in FIG.
38 .

The key A~ t device ;nrltlA~c a first laterally pl ~ Ah] e jaw 840 which is located on a first side of the first defined c~n~rl in~ 838 at a variable distance Dl from the first de~ined c~nt~rl in~-, As shown in FIGS. 37 and 50, fi,;rst jaw 840 engages a first side of key 764.

A second laterally liRpl~eAhle jaw 842 is located on a second side of the first derined cPnt-~rl in~ 838 at a variable ~c1-:~n~-e D2 ~rom the ~ir8t defined c~n~.rlin~ and engages the second side of key 764.

Jaw pnq~ n control means is coupled to first and second jaws 840 and 842 to r-intztin rliRt~n~-e Dl = D2 as jaws 840 and 842 are laterally rl i Crl i~ced toward or away rrOm rirst de~ined c~nt~l inF. 838. In the ~ of the imention illustrated in FIGS. 30A, 30B, 37, 50 and 51, the jaw position control means takes the ~orm of rack and opinion cont~rin~ means. This rack and pinion centering means in~l~ c a first rack 844 which is formed on a hori7~nt~lly t~ri~nted surface of first jaw 840 as well as 2 second rack 846 which is formed on a h~ri7~nt:~lly ` 21~7515 -oriented surface of second jaw 842.

The rack and pinion centering means also includes pinion means which engages the f irst and second racks . As shown in the drawings discussed above, the pinion means of the invention may include a ~irst pinion gear 48 which engages first rack 844 and a second pinion gear 850 which engages second rack 846. Pinion gears 848 and 850 also engage each other as shown for example in FIG. 50, .~
In another ~ - L of the invention i ~ c~r~ted in FIG. 54, the pinion means of the present invention can take the form o~ a single pinion gear 852 operating in combination with a spP;1'~ 11y con~igured first rack 844 and second rack 846 forming a part of a first jaw 840 and a second jaw 842. A set of ~aw ~ pins 854 may be provided in the FIG. 54: ' ' ' L
of the invention to prevent rotational m1c:~1i,, ' of jaws 840 and 842 as they are laterally translated back and ~orth.

In yet another: ' -'i ' of the invention as illustrated in FIG. 55, the jaw position control means int~ t~,c first gear means 856 having a ~irst geared surface 858 and a second gear means 860 having a second geared surface 862. As shown in FIG.
55, ~irst and second gear means 856 and 860 are ~iy ically positioned with respect to the first defined centerline. In addition, first geared surface 858 of first gear means 856 is 21~515 positioned to contact and engage the second geared surface 862 of the second gear means 860.

The gear-interconnected relati-,n~h;r between jaws 840 and 842 enables the jaw position control means of the invention to ~-;nl-s-;n distance Dl = D2 as jaws 840 and 842 are laterally r~ pl ;~r~ toward or away from centerline 838.

The key Rl ;,; L device further includes jaw biasing means which in the various: ir ' of the invention as~r described above take the form o~ a biasing sprir~g 864 which serves to bias jaws 840 and 842 toward centerline 838 with a 8pr~rtifiPcl lateral bia8ing force. The jaw biasing means in addition permits jaws 840 and 842 to be laterally ~ pl ~ away ~rom c~ntPtlinP 838 in ~D~ se to an OrpOc:in~ lateral force greater than the lateral biasing force, such as, for example, lateral biasing ~orces exerted during insertion and removal of the keys rrom the key ;~ device.

In the FIG. 54: a; ' Or the invention, jaw biasing means may take the form of a spring, torque tube or er~uivalent device which rotationally biases the drive shaft of pinion 852 to force jaws 840 and 842 toward the cPn~P~-l inP 838.

For all of the two-sided key ~ , L devices described above, the key cPntP~ing -- iFm for master keys 764 is 2~
faithfully Lt:pL~JduC ed or duplicated within a single cassette 792 to accomplish lateral alignment or centering of key blank 766.

Since ~!ARRett~ 782 is fabricated with key receiving apeLLuL~s 810 and 812 such that the cent~r7 inf~.s of the two ape~LuL~:s are r~ lly fixed and aligned with each other, the lateral ~1 i,; L or centering of master key 764 with respect to the centerline of aperture 812 coupled with the centering or lateral ~ ; L of key blank 766 with respect to the c~ ntprl;n~
of key receiving a~LLUL~ 812 simultAn~ous~y functions to ,align the c~nt~rl i nF- of master key 764 precisely with the ~nt~ri i n~ of key blank 766.

- To ~1 imin~te even the most remote potential for lateral m~R;~l~,; of a two-sided master key with respect to a two-sided key blank, FIGS. 50, 51, 52, 54 and 55 shows- how lateral L means ~ 'hle with the lateral :~lig t means of the single-sided key key ~1~,; device ~ccr~h~d above can readily be provided to function with the key ~l i,3 device for two-sided keys.

As best ill~LLc~6d in FIG. 51, the remote end of key set plunger 832 is c~ tæcl to a vertically oriented push bar 866 which engages the outer, vertically nrif-ntecl sllrf~n~c of jaws 842 of both the master key alignment device as well as the key blank i, device. The length of key set plunger 832, the ` ~147~1~
, configuration of push bar 866 and other related structure is ~7"~ci~nPc~ such that push bar 866 will engage and laterally displace jaws 840 and 842 of both two-sided key key A~ nt devices before either cutter wheel 742 or key follower 756 engages the bitted surfaces of either key.

The imposition of such lateral biasing forces onto the jaws of the key ~ devices guarantees , letD actuation of the j aw position control means toward the centerline to accurately center the master key relative to the key blank.
Under normal circumstances, 57-~ 57tjO7,1 of the key set button 830 will not be nP~PF~ry for the two-sided key z l i _ 1 device described immediately above.

As illustrated in FIG. 51, ~I,~rvpLiate cnnt~77~rin~ and rl z~ ~ of surface 836 of cutter head 752 permits push bar 866 to contact jaw 842 before key get plunger arm 834 cnnt;7rtc &urface 836. This ~, c r~S~ nchir of the various of key set pl~ nger 832 enables the key set plunger asse~l~bly illuDl_L~d in FIG. 51, in~l~ n~J push bar 866, to be il.Le ~ J-S7hly util1~e~ in ~ z~ ;nn with a cACcette 782, whether it ~nr ~ n~c a key s71 ~ device for a single-sided key as illl~cfr~7ted in FIG. 47 or a key zli,; ' device for a two-sided key as illustrated in FIG. 51.

The slightly '~fi~ i ' of the two-sided key ` ~ 2147~1~
A7 il; L fixture illustrated in FIGS. 52 and 53 is intended for operation with certain types of European keys in which the first and secona bitted surfaces extends along the length of the key to a distance very close to the head of the key. For such keys, it is llf cecsAry to insert the key further into the key alignment device to permit accurate and complete key duplication. The FIG.
52/FIG. 53 : ' - ir L of the invention solves this problem by providing jaws 840 and 842 which engage and center the key shank at a location outboard of key receiving apertures 810 and 812.
In addition, the use of very thin jaws 840 and 842 enables,f keys to be inserted a greater distance into r~Accett~ 782 so that the key followers and cutting wheels are able to approach to a distance closer than normal to the head Or the key.

FIGS. 56 and 57 illustrate two views of yet another -- ' of the lateral Al i; means of the present invention. mi8: ' - ~ ' of the invention in~l~lAr c a pivotable lever arm 868 which i8 spring biased by sprinq 870 away from the key as shown in the f iqures . Lateral - . ' of key set plunger 832 against the end surface 872 of lever arm 868 laterally ~iCrlAl'r~C a slider 874 within a groove which provides a quide track for slider 874 . An oval-shaped C-pel LULe: is provided in the mid-portion of ~L~ULt: 876 to A~ ' ~e relative vertical between lever arm 868 and slider 874.

For certain key cutting applications where lateral ~ 2~ 15 .
t of the master key is required but lateral ~ L of the key blank is not required, this particular configuration of lateral alignment means renders a satisfactory lateral :ll i,, ~nt function .

Referring now to FIGS. l9A, l9B, 20A and 20B, the second linear tli~rln~ ~ means of the present invention will now be `
described in detail. A prrr~-n~nt. magnet DC motor 878 lnt~ t~R a gear reduction unit of the type described above in cnnn~ct;t~n with motors 858 and 860. The reduced rotational output ve~,ocity of the motor drive shaft is coupled to rotate a c:ullaLallL velocity cam 880. The profile of constant velocity cam 880 is accurately illua~. aLed in FIG. 20 and is well known to one of ordinary skill in the cam field. -A cam follower 882 ~nt~l~lA~ a ~irst end which is coupledto engage and be tii~:plAt--~cl by cam 880. The second end of cam ft~llt,,_. 882 ig coupled by a shaft 884 and related ~LLU.;LUL~ to longitudinally reciprocate an entire ~ assembly of the key cutting machine to thereby longi~Ain~lly tli~pl;~ce the t~ ett~
~nr~lllA~n~ magter key 764 and key blan}c 766 with respect to longitudinally fixed cutter heads 750 and 752.

In FIG. 16, the rear housing 886 of the key cutting machine is directly and rigidly couplea to base 748. The front housing 888 of the key cutting machine is separated from rear 7~15 housing 886 at the point designated by reference number 890.

In FIG. l9A, the arrow designated by reference number 92 illustrates the relative movement to the right of front housing 888 as well as cassette 792 and ~ ce:ette actuator arms 792 relative to the fixed and immovable rear housing 886 of the key cutting r--hin~, As clearly illustrated in FIG. l9A, the cuttèr head assembly 750 and drive motor 758 as well as linear bearing 770 Lemain fixed as cas6ette 792 and keys 764 and 766 are 1i~plaPcl first to the right (outward) and then to the lef~,t ( inward~ during the key cutting operation .

A biasing spring 894 as provided as illustrated in FIGS.
20A and 20B to provide a reverse biasing force on the movable front housing 888/~ assembly and to facilitate the return to the closed or resting position upon ~ of the cycle.

Referring now to FIG. 39, the .~ ~ of ~CS~e~e 792 relative to fixed key follower 756 is ~ rAted~

During a single out and back key cutting cycle, the master key and key blank are drawn outward away from the longi~ n~lly fixed key follower 756 and cutting wheel 742.
Because the laterally inward biasing force exerted by the lateral biasing springs on linear bearings 770 and 772 are configured to each equal approximately eight to fourteen ounces of force ~ 2147S15 operating against the surfaces of the key blank, a very gentle cutting action takes place at all times.

As illustrated in PIG. 39, the first pass of the key blank 766 past cutting wheel 742 results in cutting away only approximately thirty percent of the depth of the ultimate cut.
Upon . ltPtit~n of the first outward rli~pl~ t of the moYeable front housing 888 past the cutting wheels, c~ntin~in~ motion of cam 880 in combination with biasing spring 894 pulls the cAt-t3ette i n~ i n~ the master key and key blank back across the cut~ing wheels in the reverse direction for a second cutting pass.
During this reverse pass of a single cutting cycle, the ninety degree or unbevelled edge 896 of the cutting wheels as illustrated in FIG. 39 travels along the second or reverse dotted line designated by re~erence number 898 and results in a harder or more aggressive cutting action. During this second, reverse pass of the cutting wheel over the key blank, the balance or about seventy percent of the key cut i5 2t~: _ i it h~`d I~ the rate of longitudinal ,~ rl ~ of the key blank past the cutting wheel is decreased to a comparatively slow velocity, the cuts of the master key can be faithfully L :~Ludu~d on the key blank in a single outward pass. For faster travel velocities, a single cycle in~l-t~lin~ an vu~-/ul-d and an inbound pass over the cutting wheels will be n~t~ ~t~l,.. y to faithfully L~v~lu~ the master and the key blank. At still faster relative ~ 2147S~5 Yelocities, r,lore th~n a ~in~le out aml ba~k cLItting ¢ycle may b~
required to acco3~pllsh accurate key dllplit-atiDn.

As the key cutting nachine is used ove~r and o ~er to duplicate many keys, the cutting whee}3 graduE~lly los~ sharpness and ultimately become ~ull ;~nough thal: thcy are not cap~ble of faithfully reproducing the ~uts of a magter k~y on a ~cey blank during a single out and back cutting p858. For this reason, the main power switch gOO o~ the key cutting machine~ i~ configured as a three position switch. In the ¢~nter position, the pow~er source is ¢o~pletely disconnected frolll the k~y cuttinq machine ~s Lllustrated in the FI~;. 18 ~lectri~al schemal:ic diagr.~m. In the second position, the key cul:ting machinQ i3 enabled to accomplish a single out and back cuttiJIg cycle alld then stop. In the third posLtion, the key cutting mAchine i3 actuAted to produce more than one cycle or to operate the k~y c:utting machine continuoUsly resulting in continuous out and back ¢utting ~yclcs .

The dyy- vyL i~te sel~ction o~ 'che nain power switch into the third position can reddily ~ ate ~or worn cutting wheels ~Jhich ~re still able t~ acc~mplish ac¢urate kPy duplic~tion, but which require more thAn a single out and back cutt$ng cycle. As a direct result of this featUre of th~s invention, key cutting wheels c~n be used to reliably duplicate a substdntially increased number of keys th~n has beer~ the ¢ase o~ith any known prior ~rt device.

21~7~15 .
As illustrated in F~GS. ~ an~l 19, a power supply is provlded to convert a conventional A~ power i-n3?ut into the appropriate DC voltage for ,e~nergizing the thr~e DC mo~ors which drive the cutter wheels and the cam drive ass~mbly. The FIG. 18 schematic h~s been simpllfied to eliminate the! AC to DC
conversion desaribed a~ove. ~he desi~ln of su~h power supplies is well known to those of ordinary skill ~n t:he e~lectronics field.

As illustra~ed in FrG. 18, a l,~ari~ y ~ power sa~ety interlocks are p~ovlded l:o dls~hle the Icey cutting loa~hine if its case is removed. In additi~n, a p~ir of Inlcr~ switahe3 gO2 are illustrated in FIGS. 1~ and 19 and inalude ac~uation buttons 904 which are depr~3sed by the opposite ends of the tip alignment plunger3 8~ As is ~ost ale~rly illustrated in FIG. 18, if a m~steL~ key g4 and a key bl~nk 766 ha~e not b~en fully ~nd equally inserted into ca3sette 794, tlp alignment plullgers 816 will not extend out th~ rear of the cassette housing ~o a distance ~u~ficient to actu~ste the s~itch actuation buttons 90 of micro switches 9~2. In this aase, the entire key cutting machine will be disabl,ed until the operator proper}y positions both the master Xey and key blank in cassette 7B2.

As illustrate~ in F~iG. 34, some double-sided keys lack A
~houider l:o provide for proper lon~itlldinal registration of the key with respect to ei~her the cuttin~ wheel or Jcey iollower o~

. ~. 2~7~1~
.
the key cutting machine. For such shoulderless, two-sided keys, the master key and key blank are longit~ in~lly registered within a cassette by designing the tip alignment plunger 816 to function as a longitudinal stop equally for both the master key and key blank .

When ~h~lll rl~rl ess two-sided keys of a shorter than normal length are encountered, a ~:h i i ng device of the type illustrated in FrG. 46 and designated by reference number 906 can be inserted into the rear vertical surface of r~-:s~ tf~ 782 to stop the~t longitudinal insertion of the tip ~l i,; plunger 816 at a shorter distance.

Various dimensions of the tip ~ , plunger 816 are critical to the proper operation of the key cutting machine of the present invention. For example, the upper or master key plunger is designated to be wider than the lower or key blank plunger. With this plunger ~n~l~lration~ operation of the key cutting machine without keys in either ~ e key receptacle will cause the upper key followers to ~i~place the cutter wheels safely away from the sides of the lower plunger. Were the plunger width design otherwise, the sides of the lower plunger would be cut away under such CiL~

Additional safety features of the invention may be described in connection with FTGS. 21, 44 and 45. A safety 21~7515 , =
follower 910 is provided as 6hown at a location slightly above the point at which cutter wheel 742 woula normally contact a key blank were it present. When both the key blank and the master key are missing from the c~otte and the key cutting machine is operated, the safety follower will immediately engage the upper edge of the tip alignment plunger 816 and will laterally deflect cutting wheel 742 away from the plunger. The operation of 6afety follower 910 thus ~L~:V~ S the cutter wheels from cutting away the sides of the plunger and the upper and lower clamping surfaces 788 and 790. A similar protective function occur,s when a narrow master key is installed in the upper cassette fixture without having a blank key in the key blank fiYture.

It will be ~l~par~ "L to those skilled in the art that the d~ los ~cl key cutting machine and key ~ ,; ' devices may be od in '~u5 ways and may assume many ~ other than the pre~erred forms srPri~c~lly set out and described above. Accordingly, it is int~n~ by the ~rr~n~ claims to cover all such modifications of the invention which fall within the true spirit and scope of the invention.

Claims (41)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A key alignment device having a longitudinal axis and a lateral axis for laterally aligning a first key including a length, upper and lower surfaces, a tip, a shoulder, a root, and a bitted surface opposite the root, the key alignment device comprising:
a. upper and lower clamping surfaces displaceable between an open position for receiving the first key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the first key and retaining the first key in a fixed lateral position with a horizontal orientation;

b. a root alignment surface laterally offset on a first side of the clamping surfaces for receiving the key root and for aligning the key root parallel to the longitudinal axis;

c. a tip alignment element for engaging the key tip and for aligning the key tip against the root alignment surface; and d. a lateral alignment element for engaging the first key at a first position displaced along the length of the key away from the key tip after the clamping surfaces have been displaced into the closed position and for laterally displacing the first key toward the root alignment surface with a lateral force sufficient to overcome the clamping forces exerted on the first key by the clamping surfaces until the key root contacts the root alignment surface to thereby align the key root with the root alignment surface and with the longitudinal axis of the key alignment device.

2. The key alignment device of Claim 1 wherein the key alignment device includes a first key alignment device located at a first elevation for laterally aligning the first key and a second key alignment device located at a second elevation for laterally aligning a second key including a length, upper and lower surfaces, a tip, a shoulder, a root and a bitted surface opposite the root, the second key alignment device having a longitudinal axis and a lateral axis and including:

a. upper and lower clamping surfaces displaceable between an open position for receiving the second key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the second key and retaining the second key in a fixed lateral position with a horizontal orientation;

b. a root alignment surface laterally offset on a first side of the clamping surfaces for receiving the key root and for aligning the key root parallel to the longitudinal axis;

c. a tip alignment element for engaging the key tip and for aligning the key tip against the root alignment surface; and d. a lateral alignment element for engaging the second key at a first position displaced along the length of the second key away from the key tip after the clamping surfaces have been displaced into the closed position and for laterally displacing the second key toward the root alignment surface with a lateral force sufficient to overcome the clamping forces exerted on the second key by the clamping surfaces until the key root contacts the root alignment surface to thereby align the key root with the root alignment surface and with the longitudinal axis of the key alignment device;

whereby the first key alignment device laterally aligns the root of the first key relative to the longitudinal axis and the second key alignment device laterally aligns the root of the second key relative to the longitudinal axis to thereby laterally align the first key with the second key.

3. The key alignment device of Claim 2 wherein the lateral position of the first key root is laterally aligned and coincident with the second key root.

4. The key alignment device of Claims 2 or 3 wherein the tip alignment element further includes longitudinal axis displacement means for initially engaging the key tip and maintaining contact with the key tip as the key is displaced along the longitudinal axis into the key alignment device.

5. The key alignment device of Claim 4 wherein the tip alignment element includes a spring biased plunger displaceable along the longitudinal axis of the key alignment device and including a tip configured to engage the key tip.

6. The key alignment device of Claim 1 wherein the lateral alignment element includes a laterally displaceable key set plunger displaceable toward and away from the first key.

7. The key alignment device of Claim 6 further including a biasing element for biasing the key set plunger away from the first key.

8. The key alignment device of Claim 1 further including a cassette for housing the key alignment device.

9. The key alignment device of Claim 2 further including a cassette for housing the first and second key alignment devices.

10. The key alignment device of Claim 1 further including a first actuator handle coupled to the upper and lower clamping surfaces and displaceable between first and second positions for displacing the clamping surfaces between the open and closed positions.

11. The key alignment device of Claim 2 further including:

a. a first actuator handle coupled to the upper and lower clamping surfaces of the first key alignment device for displacing the clamping surfaces of the first key alignment device between the open and closed positions; and b. a second actuator handle coupled to the upper and lower clamping surfaces of the second key alignment device for displacing the clamping surfaces of the second key alignment device between the open and closed positions.

12. The key alignment device of Claim 1 wherein the root alignment surface includes a linear surface parallel to the longitudinal axis and including an upper surface extending above the lower clamping surface.

13. The key alignment device of Claim 12 wherein the root alignment surface extends along substantially the entire length of the key root.

14. The key alignment device of Claim 1 wherein the upper and lower clamping surfaces are configured to maintain unobstructed access along the entire length of the bitted surface of the first key after the first key has been inserted into the key alignment device.

15. A key alignment device having a longitudinal axis and a lateral axis for laterally aligning a first key relative to a first defined, fixed centerline, the first key including a length, upper and lower surfaces, a tip, a shank, first and second side surfaces and a centerline, the key alignment device comprising:

a. a first laterally displaceable jaw located on a first side of the first defined centerline at a variable distance D1 from the first defined centerline for engaging the first side of the first key;

b. a second laterally displaceable jaw located on a second side of the first defined centerline at a variable distance D2 from the first defined centerline for engaging the second side of the key;

c. a jaw position control system coupled to the first and second jaws for maintaining distance D1 equal to distance D2 as the first and second jaws are laterally displaced toward or away from the first defined centerline;
and d. a jaw biasing element for laterally biasing the first and second jaws toward the first defined centerline with a lateral biasing force and for permitting the first and second jaws to be laterally displaced away from the first defined centerline in response to an opposing lateral force greater than the lateral biasing force.

16. The key alignment device of Claim 15 wherein the key alignment device includes a first key alignment device located at a first elevation for laterally aligning the first key and a second key alignment device located at a second elevation for laterally aligning a second key relative to a second defined, fixed centerline, the second key alignment device having a longitudinal axis and a lateral axis aligned with the longitudinal and lateral axes of the first key alignment device and including:

a. a first laterally displaceable jaw located on a first side of the second defined centerline at a variable distance D1 from the second defined centerline for engaging the first side of the second key;

b. a second laterally displaceable jaw located on a second side of the second defined centerline at a variable distance D2 from the second defined centerline for engaging the second side of the second key;

c. a jaw position control system coupled to the first and second jaws for maintaining distance D1 equal to distance D2 as the first and second jaws are laterally displaced toward or away from the second defined centerline;
and d. a jaw biasing element for laterally biasing the first and second jaws toward the second defined centerline with a lateral biasing force and for permitting the first and second jaws to be laterally displaced away from the second defined centerline in response to an opposing lateral force greater than the lateral biasing force;

whereby the first key alignment device laterally aligns the first key with the first defined centerline and the second key alignment device laterally aligns the second key with the second defined centerline to thereby laterally align the centerline of the first key with the centerline of the second key.

17. The key alignment device of Claim 16 a. wherein the first key alignment device further includes upper and lower clamping surfaces displaceable between an open position for receiving the first key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the first key to thereby exert clamping forces on the first key to retain the first key in a fixed lateral position with a horizontal orientation; and b. wherein the second key alignment device further includes upper and lower clamping surfaces displaceable between an open position for receiving the second key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the second key to thereby exert clamping forces on the second key to retain the second key in a fixed lateral position with a horizontal orientation.

18. The key alignment device of Claim 15 further including a tip alignment element for engaging the tip of the first key and for laterally aligning the key tip with the first defined centerline of the key alignment device.

19. The key alignment device of Claim 18 wherein the first and second jaws engage and laterally center the shank of the first key.

20. The key alignment device of Claim 19 wherein the first defined centerline is aligned with the longitudinal axis of the key alignment device and wherein the tip alignment element includes a longitudinal axis displacement system for engaging and centering the key tip as the key tip is initially displaced along the longitudinal axis between the first and second jaws and for maintaining continuing contact with the key tip as the key extends further along the longitudinal axis until the first and second jaws grip the key shank.

21. The key alignment device of Claim 15 wherein the jaw position control system further includes a rack and pinion centering system.

22. The key alignment device of Claim 21 wherein the rack and pinion centering system further includes a first rack formed on a surface of the first jaw and a second rack formed on a surface of the second jaw.

23. The key alignment device of Claim 22 wherein the rack and pinion centering system further includes a pinion element for engaging the first and second racks.

24. The key alignment device of Claim 23 wherein the pinion element includes a first pinion gear for engaging the first rack and a second pinion gear for engaging the second rack and wherein the first and second pinion gears engage each other.

25. The key alignment device of Claim 23 wherein the pinion element includes a single pinion gear for simultaneously engaging both the first and second racks.

26. The key alignment device of Claim 15 wherein the jaw position control system includes a first gear element having a first geared surface forming a part of the first jaw and second gear element having a second geared surface forming a part of the second jaw, the first and second gear elements being symmetrically positioned with respect to the first defined centerline with the first geared surface of the first gear element contacting the second geared surface of the second gear element.

27. The key alignment device of Claims 15 or 16 wherein the key shank includes first and second side surfaces, wherein the longitudinal axis is coincident with the first defined centerline and wherein the first and second jaws engage and operate on the first and second side surfaces of the key shank to align the centerline of the first key with the first defined centerline.

28. The key alignment device of Claim 27 further including a tip alignment element for engaging the tip of the first key and for laterally aligning the key tip with the first defined centerline.

29. The key alignment device of Claim 28 wherein the tip alignment element further includes a longitudinal axis displacement system for engaging and centering the key tip as the key tip initially engages and is displaced along the longitudinal axis between the first and second jaws and for maintaining continuing contact with the key tip as the key is further displaced along the longitudinal axis until the first and second jaws engage the first and second sides of the key shank .

30. The key alignment device of Claim 28 wherein the key alignment device is housed in a cassette assembly.

31. A key alignment device having a longitudinal axis and a lateral axis for laterally aligning first and second two-sided keys, each key including a length, upper and lower surfaces, a tip, a shank, first and second side surfaces and a centerline, the key alignment device comprising:

a. a first key alignment fixture located at a first elevation for laterally aligning the first key, including i. a first laterally displaceable jaw located on a first side of a first defined centerline laterally aligned with the longitudinal axis at a variable distance D1 from the first centerline for engaging the first side of the first key;

ii. a second laterally displaceable jaw located on a second side of the first defined centerline at a variable distance D2 from the first centerline for engaging the second side of the first key;

iii. a jaw position control system coupled to the first and second jaws for maintaining distance D1 equal to distance D2 as the first and second jaws are laterally displaced toward or away from the first defined centerline;

iv. a jaw biasing element for laterally biasing the first and second jaws toward the first defined centerline with a lateral biasing force and for permitting the first and second jaws to be laterally displaced away from the first defined centerline in response to an opposing lateral force greater than the lateral biasing force;

v. upper and lower clamping surfaces displaceable between an open position for receiving the first key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the first key and retaining the first key in a fixed lateral position with a horizontal orientation;

b. a second key alignment fixture located at a second elevation spaced apart from the first elevation for laterally aligning the second key, including i. a first laterally displaceable jaw located on a first side of a second defined centerline laterally aligned with the longitudinal axis at a variable distance D1 from the defined second centerline for engaging the first side of the second key;

ii. a second laterally displaceable jaw located on a second side of the second defined centerline at a variable distance D2 from the second defined centerline for engaging the second side of the second key;

iii. a jaw position control system coupled to the first and second jaws for maintaining distance D1 equal to distance D2 as the first and second jaws are laterally displaced toward or away from the second defined centerline;

iv. a jaw biasing element for laterally biasing the first and second jaws toward the second defined centerline with a lateral biasing force and for permitting the first and second jaws to be laterally displaced away from the second defined centerline in response to an opposing lateral force greater than the lateral biasing force; and v. upper and lower clamping surfaces displaceable between an open position for receiving the second key between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the second key and retaining the second key in a fixed lateral position with a horizontal orientation;

whereby the first key alignment fixture laterally aligns the centerline of the first key with the first defined centerline and the second key alignment fixture laterally aligns the centerline of the second key with the second defined centerline to thereby laterally align the centerline of the first key with the centerline of the second key.

32. The key alignment device of Claim 31 further including a longitudinal axis wherein the first key includes a two-sided master key and the second key includes a two-sided key blank.

33. A method for laterally aligning a first key relative to a first defined, fixed centerline within a first key alignment device having a longitudinal axis and a lateral axis, the first key including a length, upper and lower surfaces, a tip, a shank, first and second side surfaces and a centerline, comprising the steps of:

a. engaging the first side of the first key with a first laterally displaceable jaw located on the first side of the first defined centerline at a variable distance D1 from the first defined centerline;

b. engaging the second side of the first key with a second laterally displaceable jaw located on a second side of the first defined centerline at a variable distance D2 from the first defined centerline;

c. maintaining the distance D1 equal to the distance D2 as the first and second jaws are laterally displaced toward or away from the first defined centerline; and d. laterally biasing the first and second jaws toward the first defined centerline with a lateral biasing force while simultaneously permitting the first and second jaws to be laterally displaced away from the first defined centerline in response to an opposing lateral force greater than the lateral biasing force to laterally align the first key centerline with the first defined centerline.

34. The method of Claim 33 wherein the clamping forces are exerted on the first key by upper and lower clamping surfaces displaceable between an open position for receiving the first key between the clamping surfaces and a closed position for engaging and clamping the upper and lower surfaces of the first key.

35. The method of Claim 33 including the further step of maintaining unobstructed access to the first and second side surfaces of the first key while the clamping forces are being exerted on the first key.

36. The method of Claims 33 including the further step of laterally aligning a second key relative to a second defined, fixed centerline within a second key alignment device having a longitudinal axis and a lateral axis, the second key including a length, upper and lower surfaces, a tip, a shank, first and second side surfaces and a centerline, comprising the steps of:

a. engaging the first side of the second key with a first laterally displaceable jaw located on the first side of the second defined centerline at a variable distance D1 from the second defined centerline;

b. engaging the second side of the second key with a second laterally displaceable jaw located on a second side of the second defined centerline at a variable distance D2 from the second defined centerline;

c. maintaining the distance D1 equal to the distance D2 as the first and second jaws are laterally displaced toward or away from the second defined centerline;

d. laterally biasing the first and second jaws toward the second defined centerline with a lateral biasing force while simultaneously permitting the first and second jaws to be laterally displaced away from the second defined centerline in response to an opposing lateral force greater than the lateral biasing force for laterally aligning the second key centerline with the second defined centerline.

37. The method of Claim 36 wherein the first key alignment device is located at a first elevation, wherein the second key alignment device is located at a second elevation, wherein the longitudinal axis of the first key alignment device is laterally aligned with the longitudinal axis of the second key alignment device, wherein the first defined centerline is laterally aligned with the second defined centerline, and wherein lateral alignment of the first key relative to the first defined centerline and lateral alignment of the second key relative to the second defined centerline laterally aligns the centerline of the first key with the centerline of the second key.

38. The method of Claim 37 wherein the first key includes a master key and wherein the second key includes a key blank.

39. The method of Claim 37 including the further steps of:

a. exerting clamping forces on the upper and lower surfaces of the first key to retain the first key in a fixed lateral position; and b. exerting clamping forces on the upper and lower surfaces of the second key to retain the second key in a fixed lateral position.

40. The method of Claim 39 wherein the clamping forces are exerted on the first and second keys by upper and lower clamping surfaces displaceable between an open position for receiving the first and second keys between the clamping surfaces and a closed position for engaging the upper and lower surfaces of the first and second keys.

41. The method of Claim 39 including the further step of maintaining unobstructed access to the first and second side surfaces of the first and second keys while the clamping forces are being exerted on the first and second keys.