Method and apparatus for aligning keys for cutting

A device for aligning a key in a key cutting system, the key having a longitudinal reference axis, a blade with opposed sides defining a blade width and a tip at one end of the blade, the device comprising:

• a frame having an alignment axis;
• two opposed alignment jaws, each alignment jaw independently and laterally movable in the frame along a first axis of movement relative to the alignment axis of the frame, the alignment jaws moveable between an engaged position, in which the alignment jaws are spaced apart from each other a desired separation distance so that each alignment jaw contacts at least a selected portion of a respective side of the key when the key is disposed therebetween, and a disengaged position, in which the alignment jaws are spaced apart from each other farther than the desired separation distance, and wherein when the alignment jaws are in the engaged position and the key is disposed therebetween, the longitudinal reference axis of the key is positioned substantially in parallel to the alignment axis of the frame;
• a clamp having a first gripping jaw and a second gripping jaw, one of the first and second gripping jaws configured to move towards the other of the first and second gripping jaws along a second axis of movement that is substantially perpendicular to the first axis of movement and configured to engage the key after the alignment jaws have moved to the engaged position and to securely hold the key such that the opposed sides of the key are exposed for cutting when the alignment jaws return to the disengaged position;
• a motor disposed on the frame and coupled to at least one of the alignment jaws via a pinion;
• a controller operable to energize the motor for a predetermined output based upon the blade width of the key, whereby the desired separation distance between the alignment jaws is obtained;
• a worm rotatably mounted on the frame and having an outer surface defining a circumscribing groove therein and a lower end coupled to a portion of the motor so that the motor is operable to rotate the worm;
• a gear rotatably mounted on the frame and having an edge defining a plurality of gear teeth therein, each of the gear teeth of a size to be complementarily received in the groove of the worm so that rotation of the worm causes a rotation of the gear as the gear teeth of the gear interface with the groove of the worm;
• and
• means for movably coupling the gear to the pinion so that rotation of the gear causes a corresponding rotation of the pinion.

A device for aligning a key in a key cutting device, the key having a longitudinal reference axis, a blade with opposed sides defining a blade width and a tip at one end of the blade defining a blade length, the device comprising:

• a frame having an alignment axis;
• two opposed alignment jaws, each alignment jaw independently and laterally movable in the frame relative to the alignment axis of the frame, the alignment jaws moveable between an engaged position, in which the alignment jaws are spaced apart from each other a desired separation distance so that each alignment jaw contacts at least a selected portion of a respective side of the key when the key is disposed therebetween, and a disengaged position, in which the alignment jaws are spaced apart from each other farther than the desired separation distance, and wherein when the alignment jaws are in the engaged position and the key is disposed therebetween, the longitudinal reference axis of the key is positioned substantially in parallel to the alignment axis of the frame;
• a motor disposed on the frame and coupled to at least one of the alignment jaws;
• a controller operable to energize the motor for a predetermined output based upon the blade width of the key, whereby the desired separation distance between the alignment jaws is obtained;
• and
• a tip alignment mechanism movable along the alignment axis of the frame between an operable position, in which the tip alignment mechanism contacts the tip of the key when the key is disposed between the alignment jaws, and an inoperable position, in which the tip alignment mechanism is spaced apart from the tip of the key when the key is disposed between the alignment jaws, the tip alignment mechanism including a tip alignment mechanism motor coupled to the tip alignment mechanism, the controller operable to energize the tip alignment mechanism motor for a predetermined output based upon the blade length of the key.

A method of aligning a key in a key cutting device, the key having a blade having a width and a tip at one end of the blade, comprising the steps of:

• moving at least one of two opposed alignment jaws in the device to a home position in a frame, the at least one alignment jaw moving laterally relative to an alignment axis in the frame;
• detecting when the at least one alignment jaw is in the home position;
• moving the at least one alignment jaw toward the other alignment jaw and away from the home position so that the at least one alignment jaw reaches a predetermined position in which the two alignment jaws are spaced apart from each other a desired separation distance based on the dimension of the key;
• monitoring the position of the at least one alignment jaw by calculating the distance that the at least one alignment jaw moves relative to the home position so that the at least one alignment jaw moves to a predetermined position;
• moving a tip alignment mechanism along the alignment axis of the frame between a tip alignment mechanism home position and a predetermined position in which the tip of the key contacts a portion of the tip alignment mechanism when the key is positioned between the two alignment jaws;
• determining when the tip alignment mechanism is at the tip alignment mechanism home position;
• and
• monitoring the position of the tip alignment mechanism relative to the tip alignment mechanism home position by calculating an amount of distance that the tip alignment mechanism moves relative to the tip alignment mechanism home position.