`Almblad et al.
`
`I 1111111111111111 11111 111111111111111 1111111111 1111111111111111 Ill lllll llll
`US005807042A
`[11] Patent Number:
`[45] Date of Patent:
`
`5,807,042
`Sep. 15, 1998
`
`[54] METHOD AND APPARATUS FOR
`AUTOMATICALLY MAKING KEYS
`
`[76]
`
`Inventors: Robert Almblad, 440 Banbury Rd.,
`Mundelein, Ill. 60060; John Blin, 1903
`Stanton Ct., Arlington Heights, Ill.
`60004; Paul Jurczak, 1662 Vineyard
`Dr., Gurnee, Ill. 60031
`
`[21] Appl. No.: 477,224
`
`[22] Filed:
`
`Jun. 7, 1995
`
`Related U.S. Application Data
`
`[63] Continuation of PCT/US94/14862 Dec. 22, 1994.
`Int. Cl.6
`................................. B23C 3/28; GOSE 1/00
`[51]
`[52] U.S. Cl. ............................ 409/83; 250/202; 250/560;
`356/376; 364/474.03; 409/81; 409/96
`[58] Field of Search .................................. 409/82-83, 81,
`409/80, 96, 131, 132; 76/110; 348/95; 250/202,
`560, 561; 356/376, 393; 358/293, 291,
`292; 364/474.03, 474.17; 382/8
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4,300,170 11/1981 Sakamoto ................................ 358/484
`..................... 250/202 X
`4,300,836 11/1981 Holmes et al.
`4,652,738
`3/1987 Nishihara et al.
`...................... 250/202
`
`4,652,765
`4,653,104
`4,803,371
`4,845,764
`4,929,843
`5,119,190
`5,127,532
`5,128,531
`5,255,199
`5,307,151
`
`3/1987 Nishihara ................................ 250/560
`3/1987 Tamura ............................... 356/376 X
`2/1989 Durland .................................. 250/560
`7/1989 Ueda et al.
`................................. 382/8
`5/1990 Chmielewski et al. ................. 250/561
`6/1992 Lemelson .................................. 348/95
`7/1992 Cimino et al. ........................ 76/110 X
`7/1992 Fadel ..................................... 409/81 X
`10/1993 Barkman et al. .................. 364/474.17
`4/1994 Hof ......................................... 356/376
`
`FOREIGN PATENT DOCUMENTS
`
`2489535
`120944
`4093150
`5237743
`
`3/1982 France ..................................... 409/83
`6/1987
`Japan ....................................... 409/80
`3/1992
`Japan ....................................... 409/80
`9/1993
`Japan ....................................... 409/80
`
`Primary Examiner-William R. Briggs
`Attorney, Agent, or Firm-Michael R. McKenna
`
`[57]
`
`ABSTRACT
`
`The invention relates to a key making machine that auto(cid:173)
`matically extracts characteristics of an object key without
`human intervention. An object key is automatically aligned,
`key characteristics extracted and compared with known key
`manufacturers' information stored in memory, an appropri(cid:173)
`ate key blank in a robotically accessible inventory is
`selected, cut, deburred, and automatically dispensed to the
`customer.
`
`103 Claims, 19 Drawing Sheets
`
`30
`
`KEYME EX. 1004, PAGE 1
`
`
`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 1 of 19
`
`5,807,042
`
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`KEYME EX. 1004, PAGE 2
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`
`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 2 of 19
`
`5,807,042
`
`FIG. 2
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`KEYME EX. 1004, PAGE 3
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`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 3 of 19
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`5,807,042
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`KEYME EX. 1004, PAGE 4
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`
`Sep. 15, 1998
`Sep. 15, 1998
`
`Sheet 4 of 19
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`
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`KEYME EX. 1004, PAGE 5
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`KEYME EX. 1004, PAGE 5
`
`
`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 5 of 19
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`5,807,042
`
`FIG. 6
`
`68
`
`KEYME EX. 1004, PAGE 6
`
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`U.S. Patent
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`Sep. 15, 1998
`Sep. 15, 1998
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`Sep. 15, 1998
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`Sep. 15, 1998
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`Sheet 10 of 19
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`KEYME EX. 1004, PAGE 11
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`FIG. 17A
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`START
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`KEYME EX. 1004, PAGE 12
`
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`KEYME EX. 1004, PAGE 13
`
`
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`KEYME EX. 1004, PAGE 14
`
`
`
`FIG. 18
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`I BACKLIGHT I
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`OVERHEAD
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`CURRENCY
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`POSITION
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`CAMERA
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`MOTOR DRIVES
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`
`KEYME EX. 1004, PAGE 15
`
`
`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 15 of 19
`
`5,807,042
`
`FIG.
`
`FIG.
`
`114
`
`114
`
`112
`114 FIG. 19B
`
`KEYME EX. 1004, PAGE 16
`
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`KEYME EX. 1004, PAGE 17
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`FIG. 21
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`
`KEYME EX. 1004, PAGE 18
`
`
`
`U.S. Patent
`
`Sep. 15, 1998
`
`Sheet 18 of 19
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`KEYME EX. 1004, PAGE 19
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`KEYME EX. 1004, PAGE 20
`
`
`
`1
`METHOD AND APPARATUS FOR
`AUTOMATICALLY MAKING KEYS
`
`5,807,042
`
`2
`other words, if the shape of the blade, key cut codes, or
`grooves are wrong, the key will not operate the lock. Even
`though the handle may be different, if the shape of the blade,
`codes, and grooves are correct, it will still operate the lock.
`Various types of key making machines currently exist
`which identify and utilize a key manufacturer's coding to
`duplicate a customer's key. However, none of the following
`patents teaches a method or apparatus that extracts key cut
`codes of an object key absent some means of physically
`10 making referential contact with the object key. Nor do the
`patents discussed disclose a method or apparatus that
`extracts the aforementioned key attributes without physi(cid:173)
`cally making referential contact with the key after the key
`making apparatus independently positions the object key for
`15 such extraction without human intervention.
`U.S. Pat. No. 2,070,228, issued in 1935, is the seminal
`patent relating to key cut codes. The device taught measures
`relative depth of key cuts using spring loaded tumblers
`which make physical contact with the key cuts. Analysis of
`20 the slope of the key cut is not considered. The acquired data
`is then used by a locksmith to determine an appropriate key
`code.
`U.S. Pat. No. 4,090,303, relating to a key decoding
`apparatus, discloses a method of determining the original
`25 key cuts utilizing manufacturers' predetermined key cut
`depth and spacing. The key decoding apparatus disclosed
`employs an index card having sequential indexes thereon
`corresponding to a predetermined coded depth of the key
`desired to be duplicated. This card is inserted into a housing
`30 and the key to be duplicated is inserted into a slot in the
`housing where it engages an indexing member which enters
`one of the key cuts on the key and indicates on the card the
`coded depth of that key cut. The angle of the cut of the same
`key cut may also be determined. The remaining key cuts of
`35 the key may be decoded in like manner.
`The '303 disclosure does not teach the use of key cut
`spacing and depth to determine the key blank, rather this
`determination is left to the locksmith. It neither aids in the
`selection of a manufacturer's index (coding) card nor in the
`selection of a key blank. What '303 does disclose is that
`when a manufacturer's predetermined key cut depth and
`spacing index card is independently selected by the
`locksmith, the correct depth of the key cuts can be dupli-
`45 cated. The same index card is then inserted into a housing
`which includes an indexing drum having key cuts therein
`with spacing that corresponds to the predetermined coded
`spacing of the key to be duplicated.
`Some of the drawbacks to these designs are that each
`50 teaches the utilization of a manufacturer's index card data as
`the criteria to determine which key blank is appropriate. But
`an individual locksmith first has to determine which key
`blank he will use without the use of the manufacturer's index
`cards.
`Alternative technology is available in the form of U.S.
`Pat. No. 3,865,011 issued to Patriquin in 1975 which reveals
`an automatic key duplicating apparatus which discloses a
`sample device for receiving and retaining a sample key in a
`vice. The principal disadvantage of such a device is its
`requirement for proper positioning requiring the skills of a
`mechanical operator such as a locksmith.
`Additionally, U.S. Pat. No. 3,796,130 issued in 1974 to
`Gartner reveals a semi-automatic key duplicating and vend(cid:173)
`ing machine. This device requires the customer to place his
`key into one of a plurality of slots, each slot adapted to
`receive a key blade of a different cross-section correspond-
`ing to the shape of one of the key blanks in storage. Selection
`
`The applicant claims the benefit of the following prior
`filed copending international application designating the 5
`United States of America by the same inventors: Interna(cid:173)
`tional Application No. PCT/US94/14862; International Fil(cid:173)
`ing Date: Dec. 22, 1994.
`
`TECHNICAL FIELD
`
`This invention generally relates to methods and apparatus
`for automatic key making. More particularly, the invention
`extracts key attributes of an object key without mechanically
`fixturing and without physically contacting the key after the
`key making apparatus independently positions the object
`key for such extraction without human intervention.
`
`BACKGROUND OF THE INVENTION
`
`The key making art has taught us that each lock manu(cid:173)
`facturer has adopted a number of different key blanks, each
`with its own unique shape and specific groove characteris(cid:173)
`tics. Furthermore, for each key blank its manufacturer has
`assigned one or more known key cut codes that define the
`manner in which the key blank can be cut to match the
`manufacturer's lock.
`There are several thousand types of key blanks in the
`world. When a key is presented to be duplicated by a
`locksmith, he must be skilled at looking, inspecting, and
`measuring the customer's key (object key) to determine
`which key blank it is among the thousands made, and he
`must also be skilled at trace cutting the notches ( cuts or bits)
`of the customer's key into a correctly identified key blank.
`If the wrong key blank is chosen, then it will not operate in
`the customer's lock. Also, if the key cuts are not traced
`precisely, then the new key will not work in the lock.
`The traditional method of key identification is to inspect
`the handle (bow) and any stamping, the grooves, and the
`length. What has not been done, is to measure the cuts in a
`key, and then compare this information to the grooves and/or
`outer shape to determine the type of key blank.
`For each key with an elongated blade and a handle, the
`blade has longitudinal grooves determined by the manufac(cid:173)
`turer to match its locks. Notches are cut into at least one side
`of the blade. The handle normally has a hole disposed along
`the longitudinal centerline which is adapted to allow the key
`to be used on a key ring. The grooves of a key begin at the
`point that the blade extends from the handle.
`The manufacturer's key cut codes define the relationship
`between the cuts and key blank, and between one cut and
`another. The following characteristics ( attributes) are repre(cid:173)
`sentative: (1) the distance from the key shoulder to the center
`of the first cut; (2) the distance between cuts, i.e. the distance
`being measured from the center of one cut to the center of 55
`an adjacent cut; (3) the depth of each cut; (4) the angle of
`each cut; (5) the length of the flat at the bottom of each cut;
`( 6) the distance between the tip and key shoulder; and (7) the
`distance from the key shoulder to the center of the first cut.
`Once attributes, such as key outer shape, groove 60
`characteristics, and key cut features of an object key can be
`extracted, recognized, and compared to that which was
`supplied by an original key manufacturer, a new key dupli(cid:173)
`cating the original can be automatically selected and cut.
`Since the shape of the blade, grooves and key cut codes 65
`define the functional features of a key, this is the information
`that must be identified and utilized to make a proper key. In
`
`40
`
`KEYME EX. 1004, PAGE 21
`
`
`
`5,807,042
`
`3
`of the proper slots provides a means for selecting the
`appropriate key blank in storage and automatically positions
`such blank for trace cutting a duplicate profile to that of the
`customer's key. The principal disadvantages of such a
`device are that smaller keys fit into larger holes, its inability 5
`to determine the differences in key blade length or shoulder
`position which can distinguish one key blank from another,
`and the fact that this device merely duplicates the cut
`features of the customer's key which may be overly worn.
`U.S. Pat. No. 4,717,294 discloses a key cutting device 10
`which cuts key blanks by employing a set of coded depth
`keys supplied by the lock manufacturer.
`U.S. Pat. No. 4,899,391 discloses a system for identifying
`an appropriate key blank from a pattern comprised of a
`plurality of horizontal grooves of a predetermined depth and 15
`spacing taken from the image of the front profile of the key.
`The principal disadvantage of such a device is its need to be
`precisely fixtured and it needs to take images of the grooves
`from the blade tip. Length of the blade and shoulder position
`cannot be determined and discontinuities result from slight 20
`bends in the blade and/or surface imperfections. Moreover,
`keys with worn tips cannot be read accurately at all.
`U.S. Pat. No. 3,442,174 issued to Weiner et al. for a key
`blank dispensing and cutting apparatus which requires the
`assistance of the customer in selecting a slot in which to 25
`insert the blade of the key. Once having found the slot, the
`blank identification process is completed. Unfortunately, the
`apparatus only allowed for identification of the profile of the
`key and could not take into account keys having identical
`profiles and varying lengths and shoulder positions and 30
`smaller keys that fit into larger holes. Moreover, the appa(cid:173)
`ratus was limited to forty eight known key blanks, whereas
`the instant device teaches no such limitation. Additionally,
`the selection method disclosed reveals mechanical push
`rods, one for each of forty eight key blanks to push a key 35
`blank out of its respective key blank container. In the instant
`device only one robotic means for withdrawal of a key blank
`from a key dispenser is required for all stored key blanks.
`Other representative art includes U.S. Pat. Nos. 5,245, 40
`329, 5,050,462, 4,929,129, and 3,358,561.
`These earlier methods and apparatus for automatic key
`making required skill on the part of the operator to fixture
`the object key in some fashion and to have some special
`knowledge of key blanks with some kind of training. 45
`Moreover, the prior art methods to decode keys required
`instruments and gadgets that only locksmiths would be
`familiar with.
`While unrelated to the key making art, the following
`patents are nevertheless of note. U.S. Pat. No. 4,809,341 50
`teaches a method and apparatus used in semiconductor
`device fabrication for a reticle or mask image, which has a
`slight modification of reduction or magnification, using a
`comparison method in which the real image pattern is
`compared with the pattern produced from design data; and 55
`U.S. Pat. No. 4,805,224 which reveals a pattern recognition
`method and device employing second order differential
`analysis of distinctive features. Other art referenced in the
`International Search Report includes U.S. Pat. Nos. 4,143,
`582; 4,324,513; 5,129,010; 5,193,120; 4,899,391; and 60
`3,796,130.
`The citation of the foregoing publications is not an
`admission that any particular publication constitutes prior
`art, or that any publication alone or in conjunction with
`others, renders unpatentable any claim of the present appli(cid:173)
`cation. None of the cited publications is believed to detract
`from the patentability of the claimed invention.
`
`4
`Unlike the key vending machines referenced above, the
`important invention disclosed herein is designed to be
`operated by an inexperienced customer who possesses nei(cid:173)
`ther the skills of a trained locksmith nor those of a skilled
`imaging operator.
`Moreover, deficiencies in the prior art relating to proper
`sizing of the object key, elimination of distortions and
`surface flaws, and the need to mechanically fixture the object
`key have not been remedied by the art disclosed.
`No other device for automatically making keys has dis(cid:173)
`closed a non-contact means for extracting laterally exposed
`attributes, comprising three dimensional grooves, outer
`shape and laterally exposed key cuts, of an object key. Nor
`has the prior art taught a key making apparatus or method
`that automatically establishes an operative positional rela(cid:173)
`tionship between an object key and the key making machine
`without pre-fixturing the object key in a vice or some other
`holding device.
`To alleviate these problems, and others which will
`become apparent from the disclosure which follows, the
`present invention provides a key making apparatus that
`automatically establishes an operative positional relation(cid:173)
`ship between an object key and the components of the
`apparatus that extract information from an object key,
`extracts the attribute information necessary for it to deter(cid:173)
`mine the correct key blank and the correct key cut codes and
`a method of automatically cutting the correct codes in to a
`key blank despite any deficiencies in the codes of the object
`key.
`Attribute information is extracted by the instant apparatus
`automatically reading an object key and comparing the
`attributes of the object key with a master pattern memory of
`known manufacturers' keys. Then it selects the proper
`matching key blank and cuts it to the original key cut codes
`established by the manufacturer. Alternatively, the key blank
`can be trace-cut, duplicating the used attributes of the object
`key. Alternatively, key cuts hybridizing the key cut features
`of the object key and the key cut codes of a known
`manufacturer's key may be determined for use with the
`corresponding key blank.
`
`ADVANTAGES OF THIS INVENTION
`Unlike the foregoing devices which teach structures that
`require fixturing an object key requiring the precision of a
`trained locksmith to properly place the key within a vice or
`similar holding device, the instant invention allows the key
`to be loosely situated within a specified but yet broader area.
`Thereafter, the key making machine operates automatically
`to position the key, to extract key attributes so that a
`corresponding key blank stored in the machine can be
`identified, and corresponding key cut codes can be identified
`and cut into the corresponding key blank to make a new key
`conforming to the manufacturer's original specifications.
`Every necessary aspect of the key making process has been
`incorporated into the preferred embodiments of the instant
`apparatus.
`Furthermore, a superior method and apparatus is dis-
`closed herein which allows the internal grooves to be
`identified more accurately. The prior art discussed above
`reveals a method for looking down the front profile of the
`key, that is, looking longitudinally from the tip of the blade.
`This method is subject to inaccuracies due to distortions
`from wear and blade bending. Moreover, the system is
`unable to determine blade length, shoulder position, or
`65 attribute information.
`By combining a backlighting method, which sees the
`outer shape of the key, including its key cut features, and a
`
`KEYME EX. 1004, PAGE 22
`
`
`
`5,807,042
`
`5
`light stripe method, which obliquely projects a light stripe on
`to the blade producing a multi-dimensional image, the
`disadvantages of the prior art have been overcome.
`Another embodiment of the instant invention comprises a
`non-contact method for extracting attributes of an object
`key. In this method and apparatus both externally exposed
`and laterally protected attributes may be extracted. It
`involves the use of a means for receiving object images,
`such as a camera, which has a lens capable of viewing a
`shallow focal plane.
`The disclosed embodiments of the instant invention can
`identify and produce not only American made keys, but
`those of Europe and throughout the world having laterally
`protected cuts and curved grooves as well.
`The instant automatic key making apparatus provides an
`efficient and convenient means of making new keys. The
`apparatus of the present invention performs all of the
`required functions to achieve the objective of making a key
`that meets the specifications of the original manufacturer.
`Additionally, the methods disclosed provide that the appa- 20
`ratus may acquire new key information which may be added
`to the machine's database, thus, allowing the range of
`applicable customer keys to expand.
`Moreover, the methods disclosed herein requires no skill
`on the part of the operator or any knowledge of keys.
`Particularly when compared to the foregoing devices, the
`instant invention is user-friendly.
`The embodiments of the disclosed invention reveal a
`self-service key making apparatus requiring few instructions
`and little or no skill or special knowledge on the part of the
`customer. Ease of use is a critical advantage. It is no harder
`to use than a photocopy machine-no greater level of
`complexity is required.
`Still other advantages will be apparent from the disclosure 35
`that follows.
`
`6
`the light stripe generator and camera of the automatic key
`making apparatus of the present invention;
`FIG. 2 is a fragmentary side elevation view of a preferred
`embodiment of a transparent section of the object key
`5 supporting means with an object key disposed in a sloped
`position thereon of the automatic key making apparatus of
`the present invention;
`FIG. 3 is a fragmentary side elevation view of a preferred
`embodiment of the transparent section of the object key
`10 supporting means of FIG. 2 with the handle section lowered
`and horizontal light obstructed by the blade of the object key
`disposed flatly on the blade section thereof of the automatic
`key making apparatus of the present invention;
`FIG. 4 is a cut-away perspective view of a preferred
`15 embodiment of the rotatable object key supporting means
`showing the backlighting means, the horizontal adjustment
`means, and tandem movement of the assembly of the light
`stripe generator and camera of the automatic key making
`apparatus of the present invention;
`FIG. 5 is a perspective view of a preferred embodiment of
`the key effector base showing the subbase linear slide
`motion guides;
`FIG. 6 is a partially exploded perspective view showing
`a positional relationship of a preferred embodiment of a key
`25 dispenser cup to a key holding container and the key
`effector, respectively;
`FIG. 7 is a perspective view of a preferred embodiment of
`the dispenser cup showing its hinged door;
`FIG. 8 is a perspective view of a preferred embodiment of
`30 the key effector showing a clamp and spring biased block in
`an exploded format;
`FIG. 9 is a perspective view of a preferred embodiment of
`the key holding container showing its relationship to one key
`blank of a stack of key blanks;
`FIG. 10 is a side elevation view of a preferred embodi(cid:173)
`ment of the dispenser cup with the hinged door closed and
`the key holding container, shown in phantom, disposed
`therein, and the clamp and rod of the key effector in a
`pre-engagement position;
`FIG. 11 is a side elevation view of a preferred embodi(cid:173)
`ment of the dispenser cup with the hinged door engaged by
`the clamp of the key effector to open same and the key
`holding container, shown in phantom, disposed therein, and
`a pin disposed upwardly on the rod engaged with a hole in
`45 the handle of a key blank;
`FIG. 12 is a partial cut-away side elevation view of a
`preferred embodiment of the key effector with the key blank
`secured in position for cutting;
`FIG. 13 is a side elevation view of a preferred embodi-
`ment of a rotatable cutting wheel and associated anvils for
`cutting a key blank;
`FIG. 14 is a partial perspective view of a preferred
`embodiment of a spatial orthogonal array of the dispenser
`55 cups and associated key holding containers in relation to a
`representation of the key effector, shown in phantom;
`FIG. 15 is a top plan view of representative shapes of
`different keys;
`FIG. 16 is a top plan view of a cut key and representative
`60 light stripes projected thereon, with a representation of the
`characteristics of the key from the respective light stripes;
`FIG. 17 is a flow diagram of a preferred embodiment of
`the operation of the automatic key making apparatus of the
`present invention (FIGS. 17 A, 17B and l 7C, taken together
`65 diagram another preferred embodiment of the operation of
`the automatic key making apparatus of the present
`invention);
`
`50
`
`SUMMARY OF THE INVENTION
`The invention relates to methods and apparatus for auto(cid:173)
`matically making keys by extracting key cut codes, or other 40
`attributes, of an object key without physically contacting the
`key in such extraction process. Additionally, the key making
`apparatus may independently position the object key for
`such extraction without human intervention.
`The key making apparatus may comprise a transparent
`section on which an object key may be supported which is
`rotatable, and a backlighting means is used to pass light
`through the transparent section and project an image of th