System and method for reproducing coded keys

For use in a key duplicating system having a base, a rotary cutter and stylus respectively coupled to the base, and a carriage having a clamping vise secured thereto, the vise being positionable by the carriage in two different directions relative to the rotary cutter and stylus so as to bring a working surface of a key blank held by the vise into engagement with the rotary cutter, a device for adapting the system to machine keys from a code when an original key is not available, the device comprising:

• a holder carrying a plurality of matrix keys in fixed registration relative to one another, the holder being securable to the carriage for synchronized movement therewith and further being manipulable to position any selected one of the matrix keys in fixed alignment with a key blank held by the vise without a need to remove from the holder any matrix key already retained,
• wherein each respective matrix key held by the holder has a common notch spacing and a notch depth representative of a correspondingly different code digit specified by a lock manufacturer
• whereby movement of the carriage so as to urge a first respective notch location, of a first selected matrix key aligned in a common plane with a key blank, toward registration with the stylus causes the rotary cutter to remove material from the key blank to form a first corresponding notch location thereon, and
• whereby movement of the carriage so as to urge a second respective notch location, of a second selected matrix key aligned in a common plane with the key blank, toward registration with the stylus causes the rotary cutter to remove material from the key blank to form a second corresponding notch location thereon.

A system for reproducing coded keys based on reference to notch spacing and depth of a plurality of matrix keys, each respective matrix key of a set having a common notch spacing and a notch depth representative of a correspondingly different code digit specified by a lock manufacturer, the system comprising:

• a base;
• a rotary cutter coupled to the base,
• a rotary tool for driving the cutter, the rotary tool including an elongated dielectric housing, an on-off switch, and a shaft extending at least 3 cm from the housing for driving the cutter,
• a stylus coupled to the base;
• a carriage having a clamping vise secured thereto, the vise being positionable by the carriage in two orthogonal directions relative to the rotary cutter and stylus no as to bring a working surface of a key blank held by the vise into engagement with the rotary cutter;
• and
• a holder carrying a plurality of matrix keys in fixed registration relative to one another, the holder being securable to the carriage for synchronized movement therewith and further being manipulable to position any selected one of the matrix keys in fixed alignment with a key blank held by the vise without a need to remove from the holder any matrix key already retained,
• whereby movement of the carriage so as to urge a first respective notch location, of a first selected matrix key aligned in a common plane with the key blank, toward registration with the stylus causes the rotary cutter to remove material from the key blank to form a first corresponding notch location thereon, and
• whereby movement of the carriage so as to urge a second respective notch location, of a second selected matrix key aligned in a common plane with the key blank, toward registration with the stylus causes the rotary cutter to remove material from the key blank to form a second corresponding notch location thereon.