Plug for lock system and associated method of assembly

A method of assembling a lock plug, the method comprising:

• selecting an insert component from a plurality of insert components;
• assembling components of a blocking mechanism with the insert component partially defining a keyway;
• and
• assembling the insert component to a primary component of the lock plug to form a plug body, the primary component partially defining the keyway, the plug body having a solid of revolution shape defined around an axis, the plug insert component generally shaped as a segment of the solid of revolution shape, the segment having a height lesser than a radius of the solid of revolution shape around the axis;
• wherein the assembling the insert component to the primary component includes securing the insert component to the primary component with a retaining ring, the retaining ring concentric to the axis.

A modular lock plug configured to be rotatably mounted in a lock housing, the lock plug comprising:

• a plug body rotatably mountable within the lock housing for rotation relative to the lock housing around a rotation axis, the plug body having a solid of revolution shape, the plug body comprising an insert component assembled to a primary component;
• a keyway defined in the plug body, the keyway having a length parallel to the rotation axis, the keyway adapted to receive a key blade matching a cross-sectional shape of the keyway;
• and
• a blocking mechanism operable to protrude into the keyway, the blocking mechanism configured to prevent the plug from rotating unless actuated by the key blade, the blocking mechanism integrated into the plug body insert component;
• wherein the insert component is selected from a plurality of insert components each corresponding to at least one of a plurality of key blades, each insert component interchangeable with another insert component;
• wherein the blocking mechanism has a tumbler biased towards the key blade and configured to engage and be pushed back by an abutment of the key blade, the mechanism unblocking the rotation when pushed back by an unblocking distance;
• and
• wherein the blocking mechanism has a rack integrated to the tumbler, and a pinion rotatable by the rack around a pinion axis to selectively block or unblock the rotation of the lock plug.