Design History

Here is a brief history of earlier designs:

Series 1
1) Original prototype for New Beetle and Karmann Ghia,
2) Key connected to motor shaft directly with two external set screws.
3) Key "wobble" possible (about 1/16 to 1/18 inch).
4) Key tabs machined by contractor shop at about $80 per key!
5) All joints TIG welded.

Series 2
1) Cost reduction in key tabs using water jet cutting which
allows more complex shapes.
2) Key larger than Series 1.
3) Key tabs TIG welded with base and shaft cap brazed together.
4) Motor coupling machined to motor centerline to reduce wobble.
5) Key held on with a tamper resistant screw on end of shaft.
5) Overload protector added.

Series 3
1) Smaller key size to use standard shipping boxes and standard metal sheet size.
2) Three shapes added (rounded square, round and "Lilliput")
2) All seams TIG welded (fatique failures found in Series 2 braze welds).
3) Printed circuit board added for overload protection.
4) Billet base added to allow removal of key during automatic car washes.

Series 4
1) Smaller oval shaped key size for less protrusion behind the vehicle.
2) Fixed position and free-spinning designs without electric gearmotors
added for lower cost.
3) Mounting option with frame under license plate.

Series 5
1) Smaller oval shaped key size adapted to mount on rear wiper motor shaft.
2) Fixed oscillating design or custom one-way clutch for one direction rotation.

Series 6
1) Series 3 design improved into 2-piece shaft for easier key removal.
This replaces the heavier and more expensive billet base design.
2) Vinyl boot included to cover drive shaft.
3) Change to smaller gearmotor with custom drive shaft assembly
which includes a large bearing ball bearing.
4) Added high intensity LEDs to replace license plate lights on some
designs for older VW Bugs and the Nash Metropolitan.

Series 7
1) Two-piece shaft design with larger diameter for a stepper
motor for lower noise and precise positioning when stopped
2) Added cost of drive electronics for stepper motor.
3) Still in development

Series 8
1) Smaller oval shaped key size for less protrusion behind the vehicle.
2) Customer design to replace the rear wiper motor.
3) Allows continuous rotation over the Series 5 design.

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Revised: 1/17/07