Method and apparatus for aligning and cutting single-sided and double-sided keys

A method for duplicating a master key onto a key blank, the master key and key blank each including a length, an upper surface, a lower surface, a tip, a shoulder, and a first bitted surface, the bitted surface of the master key including cuts extending laterally between a first lateral position and a second lateral position, comprising the steps of:

• a. providing a laterally displaceable first cutter head having a first key follower positioned at a first elevation and including a vertical key following edge surface, a spaced apart first cutting wheel positioned at a second elevation and including a cutting edge longitudinally aligned with the vertical edge surface of the first key follower, and a first motor coupled to rotate the first cutting wheel in a first direction;
• b. positioning the master key at the first elevation with a horizontal orientation to engage the first bitted surface of the master key with the vertical edge surface of the first key follower while maintaining unobstructed access to the first bitted surface of the master key as the master key and the first key follower are longitudinally translated relative to each other;
• c. positioning the key blank at the second elevation with a horizontal orientation to engage the first bitted surface of the key blank with the first cutter wheel while maintaining unobstructed access to the first bitted surface of the key blank as the key blank and the first cutting wheel are longitudinally translated relative to each other;
• d. laterally biasing the first cutter head toward the master key and key blank without the assistance of gravitational forces such that the vertical edge surface of the first key follower engages the first bitted surface of the master key and the cutting edge of the first cutting wheel engages the first bitted surface of the key blank at longitudinally aligned locations;
• e. laterally displacing the first key follower relative to a first horizontal plane and the first cutting wheel relative to a second horizontal plane toward and away from the first bitted surfaces of the master key and the key blank between the first and second lateral positions to enable the first cutter head to laterally follow and duplicate the first bitted surface of the master key onto the first bitted surface of the key blank without increasing or decreasing the elevation of the first cutter head;
• and
• f. simultaneously longitudinally displacing the first bitted surface of the master key and the first key follower relative to each other at the first elevation and simultaneously longitudinally displacing the first bitted surface of the key blank and the first cutting wheel relative to each other at the second elevation to reproduce the first bitted surface of the master key on the first bitted surface of the key blank.

A key cutting machine having a longitudinal axis and a horizontally oriented lateral axis for duplicating a master key onto a key blank, the master key and key blank each including a length, an upper surface, a lower surface, a tip, a shoulder, and a first bitted surface, the bitted surface of the master key including cuts extending laterally between a first lateral position and a second lateral position, the key cutting machine comprising:

• a. a base;
• b. a laterally displaceable first cutter head having a first key follower positioned at a first elevation and including a vertical key following edge surface, a spaced apart first cutting wheel positioned at a second elevation and including a cutting edge longitudinally aligned with the vertical key following edge surface and a first motor coupled to rotate the first cutting wheel in a first direction;
• c. a first linear displacement element coupled to the first cutter head for simultaneously laterally displacing the first key follower relative to a first horizontal plane and the first cutting wheel relative to a second horizontal plane toward and away from the first bitted surfaces of the master key and the key blank between the first and second lateral positions to enable the first cutter head to laterally follow and duplicate the first bitted surface of the master key onto the first bitted surface of the key blank without increasing or decreasing the elevation of the first cutter head;
• d. a key positioning fixture including
• i. a first key positioning fixture for horizontally positioning and vertically aligning the master key such that the first bitted surface of the master key engages the vertical key following edge surface of the first key follower and for maintaining unobstructed access to the first bitted surface of the master key as the key positioning fixture is longitudinally translated relative to the first key follower;
• ii. a second key positioning fixture for horizontally positioning and vertically aligning the key blank such that the first bitted surface of the key blank engages the cutting edge of the cutting wheel and for maintaining unobstructed access to the first bitted surface of the key blank as the key positioning fixture is longitudinally translated relative to the first cutting wheel;
• and
• e. a second linear displacement element for longitudinally displacing the key positioning fixture and the first cutter head relative to each other without increasing or decreasing the elevation of the first cutter head to thereby longitudinally displace the first bitted surface of the master key and the first key follower relative to each other along the longitudinal axis at the first elevation and to longitudinally displace the first bitted surface of the key blank and the first cutting wheel relative to each other along the longitudinal axis at the second elevation to reproduce the first bitted surface of the master key on the first bitted surface of the key blank.