Patent Publication Number: US-7591161-B2

Title: Methods and apparatus for controlling flare in roll-forming processes

Description:
RELATED APPLICATIONS 
   The issued patent is a continuation of U.S. patent application Ser. No. 10/780,413, filed on Feb. 17, 2004 now U.S. Pat. No. 7,111,481, the specification of which is incorporated herein by reference in its entirety. 

   FIELD OF THE DISCLOSURE 
   The present disclosure relates generally to roll-forming processes and, more particularly, to methods and apparatus for controlling flare in roll-forming processes. 
   BACKGROUND 
   Roll-forming processes are typically used to manufacture formed components such as structural beams, siding, ductile structures, and/or any other component having a formed profile. A roll-forming process may be implemented using a roll-former machine or system having a sequenced plurality of forming passes. Each of the forming passes typically includes a roller assembly configured to contour, shape, bend, and/or fold a moving material. The number of forming passes required to form a component may be dictated by the material characteristics of the material (e.g., the material strength) and the profile complexity of the formed component (e.g., the number of bends, folds, etc. needed to produce a finished component). The moving material may be, for example, a metallic strip material that is unwound from coiled strip stock and moved through the roll-former system. As the material moves through the roll-former system, each of the forming passes performs a bending and/or folding operation on the material to progressively shape the material to achieve a desired profile. For example, the profile of a C-shaped component (well-known in the art as a CEE) has the appearance of the letter C when looking at one end of the C-shaped component. 
   A roll-forming process may be based on post-cut process or in a pre-cut process. A post-cut process involves unwinding a strip material from a coil and feeding the strip material through a roll-former system. In some cases, the strip material is first leveled, flattened, or otherwise conditioned prior to entering the roll-former system. A plurality of bending and/or folding operations is performed on the strip material as it moves through the forming passes to produce a formed material having a desired profile. The formed material is then removed from the last forming pass and moved through a cutting or shearing press that cuts the formed material into sections having a predetermined length. In a pre-cut process, the strip material is passed through a cutting or shearing press prior to entering the roll-former system. In this manner, pieces of formed material having a pre-determined length are individually processed by the roll-former system. 
   Formed materials or formed components are typically manufactured to comply with tolerance values associated with bend angles, lengths of material, distances from one bend to another, etc. In particular, bend angles that deviate from a desired angle are often associated with an amount of flare. In general, flare may be manifested in formed components as a structure that is bent inward or outward from a desired nominal position. For example, a roll-former system or portion thereof may be configured to perform one 90 degree bend on a material to produce an L-shaped profile. The roll-former system may be configured to form the L-shaped profile so that the walls of the formed component having an L-shaped profile form a 90 degree angle within, for example, a +/−5 degree flare tolerance value. If the first structure and the second structure do not form a 90 degree angle, the formed component is said to have flare. A formed component may be flared-in, flared-out, or both such as, for example, flared-in at a leading end and flared-out at a trailing end. Flare-in is typically a result of overforming and flare-out is typically a result of underforming. Additionally or alternatively, flare may be a result of material characteristics such as, for example, a spring or yield strength characteristic of a material. For example, a material may spring out (i.e., tend to return to its shape prior to a forming operation) after it exits a roll-forming pass and/or a roll-former system. 
   Flare is often an undesirable component characteristic and can be problematic in many applications. For example, formed materials are often used in structural applications such as building construction. In some cases, strength and structural support calculations are performed based on the expected strength of a formed material. In these cases, tolerance values such as flare tolerance values are very important because they are associated with an expected strength of the formed materials. In other cases, controlling flare tolerance values is important when interconnecting (e.g., welding) one formed component to another formed component. Interconnecting formed components typically requires that the ends of the formed components are substantially similar or identical. 
   Traditional methods for controlling flare typically require a significant amount of setup time to control flare uniformly throughout a formed component. Some roll-former systems are not capable of controlling flare uniformly throughout a formed component. In general, one known method for controlling flare involves changing positions of roller assemblies of forming passes, moving a material through the forming passes, measuring the flare of the formed components, and re-adjusting the positions of the roller assemblies based on the measured flare. This process is repeated until the roller assemblies are set in a position that reduces the flare to be within a specified flare tolerance. The roller assemblies then remain in a fixed position (i.e., static setting) throughout the operation of the roll-former system. Another known method for controlling flare involves adding a straightener fixture or flare fixture in line with the forming passes of a roll-former system. The straightener fixture or flare fixture includes one or more idle rollers that are set to a fixed position and apply pressure to flared surfaces of a formed component to reduce flare. Unfortunately, static or fixed flare control methods, such as those described above, allow flare to vary along the length of the formed components. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is an elevational view and  FIG. 1B  is a plan view of an example roll-former system that may be used to form components from a moving material. 
       FIGS. 2A and 2B  are isometric views of a C-shaped component and a Z-shaped component, respectively. 
       FIG. 3  is an example of a sequence of forming passes that may be used to make the C-shaped component of  FIG. 2A . 
       FIGS. 4A and 4B  are isometric views of an example forming unit. 
       FIG. 5  is another isometric view of the example forming unit of  FIGS. 4A and 4B . 
       FIG. 6  is an elevational view of the example forming unit of  FIGS. 4A and 4B . 
       FIGS. 7A and 7B  are more detailed views of roller assemblies that may be used in the example forming unit of  FIGS. 4A and 4B . 
       FIG. 8A  is an isometric view and  FIGS. 8B and 8C  are plan views of example C-shaped components having underformed and/or overformed ends. 
       FIG. 9  is an example time sequence view depicting the operation of a flange roller. 
       FIG. 10  is a plan view of an example flare control system that may be used to control the flare associated with a roll-formed component. 
       FIG. 11  is a flow diagram depicting an example manner in which the example flare control system of  FIG. 10  may be configured to control the flare of a formed component. 
       FIG. 12  is a flow diagram of an example feedback process that may be used to determine the positions of an operator side flange roller and a drive side flange roller. 
       FIG. 13  is a flow diagram depicting another example manner in which the example flare control system of  FIG. 10  may be configured to control the flare of a formed component. 
       FIG. 14  is a block diagram of an example system that may be used to implement the example methods described herein. 
       FIG. 15  is an example processor system that may be used to implement the example methods and apparatus described herein. 
   

   DETAILED DESCRIPTION 
     FIG. 1A  is an elevational view and  FIG. 1B  is a plan view of an example roll-former system that may be used to form components from a strip material  102 . The example roll-former system  100  may be part of, for example, a continuously moving material manufacturing system. Such a continuously moving material manufacturing system may include a plurality of subsystems that modify or alter the material  102  using processes that, for example, unwind, fold, punch, and/or stack the material  102 . The material  102  may be a metallic strip or sheet material supplied on a roll or may be any other metallic or non-metallic material. Additionally, the continuous material manufacturing system may include the example roll-former system  100  which, as described in detail below, may be configured to form a component such as, for example, a metal beam or girder having any desired profile. For purposes of clarity, a C-shaped component  200  ( FIG. 2A ) having a C-shaped profile (i.e., a CEE profile) and a Z-shaped component  250  ( FIG. 2B ) having a Z-shaped profile (i.e., a ZEE profile) are described below in connection with  FIGS. 2A and 2B . The example components  200  and  250  are typically referred to in the industry as purlins, which may be formed by performing a plurality of folding or bending operations on the material  102 . 
   The example roll-former system  100  may be configured to form, for example, the example components  200  and  250  from a continuous material in a post-cut roll-forming operation or from a plurality of sheets of material in a pre-cut roll-forming operation. If the material  102  is a continuous material, the example roll-former  100  may be configured to receive the material  102  from an unwind stand (not shown) and drive, move, and/or translate the material  102  in a direction generally indicated by the arrow  104 . Alternatively, the example roll-former  100  may be configured to receive the material  102  from a shear (not shown) if the material  102  is a pre-cut sheet of material (e.g., a fixed length of a strip material). 
   The example roll-former system  100  includes a drive unit  106  and a plurality of forming passes  108   a - g . The drive unit  106  may be operatively coupled to and configured to drive portions of the forming passes  108   a - g  via, for example, gears, pulleys, chains, belts, etc. Any suitable drive unit such as, for example, an electric motor, a pneumatic motor, etc. may be used to implement the drive unit  106 . In some instances, the drive unit  106  may be a dedicated unit that is used only by the example roll-former system  100 . In other instances, the drive unit  106  may be omitted from the example roll-former system  100  and the forming passes  108   a - g  may be operatively coupled to a drive unit of another system in a material manufacturing system. For example, if the example roll-former  100  is operatively coupled to a material unwind system having a material unwind system drive unit, the material unwind system drive unit may be operatively coupled to the forming passes  108   a - g.    
   The forming passes  108   a - g  work cooperatively to fold and/or bend the material  102  to form the formed example components  200  and  250 . Each of the roll-forming passes  108   a - g  may include a plurality of forming rolls described in connection with  FIGS. 4 through 6  that may be configured to apply bending forces to the material  102  at predetermined folding lines as the material  102  is driven, moved, and/or translated through the example roll-former system  100  in the direction  104 . More specifically, as the material  102  moves through the example roll-former system  100 , each of the forming passes  108   a - g  performs an incremental bending or forming operation on the material  102  as described in detail below in connection with  FIG. 3 . 
   In general, if the example roll-former system  100  is configured to form a ninety-degree fold along an edge of the material  102 , more than one of the forming passes  108   a - g  may be configured to cooperatively form the ninety-degree angle bend. For example, the ninety-degree angle may be formed by the four forming passes  108   a - d , each of which may be configured to perform a fifteen-degree angle bend in the material  102 . In this manner, after the material  102  moves through the forming pass  108   d , the ninety-degree angle bend is fully formed. The number of forming passes in the example roll-former system  100  may vary based on, for example, the strength, thickness, and type of the material  102 . In addition, the number of forming passes in the example roll-former system  100  may vary based on the profile of the formed component such as, for example, the C-shape profile of the example C-shaped component  200  and the Z-shape profile of the example Z-shaped component  250 . 
   As shown in  FIG. 1B , each of the forming passes  108   a - d  includes a pair of forming units such as, for example, the forming units  110   a  and  110   b  that correspond to opposite sides of the material  104 . Additionally, as shown in  FIG. 1B , the forming passes  108   e - g  include staggered forming units. The forming units  110   a  and  110   b  may be configured to perform bends on both sides or longitudinal edges of the material  102  in a simultaneous manner. As the material  102  is incrementally shaped or formed by the forming passes  108   a - g , the overall or effective width of the material  102  is reduced. As the overall width of the material  102  is reduced, forming unit pairs (e.g., the forming units  110   a  and  110   b ) or forming rolls of the forming unit pairs may be configured to be closer together to further bend the material  102 . For some forming processes, the width of the material  102  may be reduced to a width that would cause the rolls of opposing forming unit pairs to interfere (e.g., contact) each other. For this reason, each of the forming passes  108   e - g  is configured to include staggered forming units. 
     FIGS. 2A and 2B  are isometric views of the example C-shaped component  200  and the example Z-shaped component  250 , respectively. The example C-shaped component  200  and the example Z-shaped component  250  may be formed by the example roll-former system  100  of  FIGS. 1A and 1B . However, the example roll-former system  100  is not limited to forming the example components  200  and  250 . As shown in  FIG. 2A , the C-shaped component  200  includes two return structures  202   a  and  202   b , two flange structures  204   a  and  204   b , and a web structure  206  disposed between the flange structures  204   a  and  204   b . As described below in connection with  FIG. 3 , the return structures  202   a - b , the flange structures  204   a - b , and the web structure  206  may be formed by folding the material  102  at a plurality of folding lines  208   a ,  208   b ,  210   a , and  210   b.    
     FIG. 3  is an example of a sequence of forming passes  300  that may be used to make the example C-shaped component  200  of  FIG. 2A . The example forming pass sequence  300  is illustrated using the material  102  ( FIG. 1A ) and a forming pass sequence line  302  that shows a plurality of forming passes p 0 -p 5  associated with folds or bends that create a corresponding one of a plurality of component profiles  304   a - g . The forming passes p 0 -p 5  may be implemented by, for example, any combination of the forming passes  108   a - g  of  FIGS. 1A and 1B . As described below, the folds or bends associated with the passes p 0 -p 5  are applied along the plurality of folding lines  208   a - b  and  210   a - b  ( FIG. 2A ) to create the return structures  202   a - b , the flange structures  204   a - b , and the web structure  206  shown in  FIG. 2A . 
   As depicted in  FIG. 3 , the material  102  has an initial component profile  304   a , which corresponds to an initial state on the forming pass sequence line  302 . The return structures  202   a - b  are formed in passes p 0  through p 2 . The pass p 0  is associated with a component profile  304   b . The pass p 0  may be implemented by, for example, the forming pass  108   a , which may be configured to perform a folding operation along folding lines  208   a - b  to start the formation of the return structures  202   a  and  202   b . The material  102  is then moved through the pass p 1 , which may be implemented by, for example, the forming pass  108   b . The pass p 1  performs a further folding or bending operation along the folding lines  208   a  and  208   b  to form a component profile  304   c , after which the pass p 2  receives the material  102 . The pass p 2 , which may be implemented by the forming pass  108   c , may be configured to perform a final folding or bending operation at the folding lines  208   a  and  208   b  to complete the formation of the return structures  202   a  and  202   b  as shown in a component profile  304   d.    
   The flange structures  204   a  and  204   b  are then formed in passes p 3  through p 5 . The pass p 3  may be implemented by the forming pass  108   e , which may be configured to perform a folding or bending operation along folding lines  210   a  and  210   b  to form a component profile  304   e . The pass p 4  may then perform a further folding or bending operation along the folding lines  210   a - b  to form a component profile  304   f . The component profile  304   f  may have a substantially reduced width that may require the pass p 4  to be implemented using staggered forming units such as, for example, the staggered forming units of the forming pass  108   e . In a similar manner, a pass p 5  may be implemented by the forming pass  108   f  and may be configured to perform a final folding or bending operation along the folding lines  210   a  and  210   b  to complete the formation of the flanges  204   a - b  to match a component profile  304   g . The component profile  304   g  may be substantially similar or identical to the profile of the example C-shaped component  200  of  FIG. 2A . Although the C-shaped component  200  is shown as being formed by the six passes p 0 -p 5 , any other number of passes may be used instead. 
     FIGS. 4A and 4B  are isometric views of an example forming unit  400 . The example forming unit  400  or other forming units substantially similar or identical to the example forming unit  400  may be used to implement the forming passes  108   a - g . The example forming unit  400  is shown by way of example as having an upper side roller  402   a , a lower side roller  402   b , and a return or flange roller  404  (i.e., a flange roller  404 ) (clearly shown in  FIG. 4B ). 
   Any material capable of withstanding the forces associated with the bending or folding of a material such as, for example, steel, may be used to implement the rollers  402   a - b  and  404 . The rollers  402   a - b  and  404  may also be implemented using any shape suitable for performing a desired bending or folding operation. For example, as described in greater detail below in connection with  FIGS. 7A and 7B , the angle of a forming surface  406  of the flange roller  404  may be configured to form a desired structure (e.g., the return structures  202   a - b  and/or the flange structures  204   a - b ) having any desired angle. 
   The positions of the rollers  402   a - b  and  404  may be adjusted to accommodate, for example, different thickness materials. More specifically, the position of the upper side roller  402   a  may be adjusted by a position adjustment system  408 , the position of the lower side roller  402   b  may be adjusted by a position adjustment system  410 , and the position of the flange roller  404  may by adjusted by a position adjustment system  412 . As shown in  FIG. 4A , the position adjustment system  408  is mechanically coupled to an upper side roller support frame  414   a . As the position adjustment system  408  is adjusted, the upper side roller support frame  414   a  causes the upper side roller  402   a  to move along a curved path toward or away from the flange roller  404 . In a similar manner, the position adjustment system  410  is mechanically coupled to a lower side roller support frame  414   b  via an extension element  416  (e.g., a push rod, a link arm, etc.). As shown clearly in  FIG. 5 , adjustment of the position adjustment system  410  moves the extension element  416  to cause the lower side roller support frame  414   b  to swing the lower side roller  402   b  toward or away from the flange roller  404 . The angle adjustment of the flange roller  404  with respect to the position adjustment system  410  is described below in connection with  FIG. 5 . 
     FIG. 5  is another isometric view of the example forming unit  400  of  FIGS. 4A and 4B . In particular, the position adjustment systems  410  and  412 , the extension element  416 , and the lower side roller support frame  414   b  of  FIG. 4  are clearly shown in  FIG. 5 . The position adjustment system  412  may be mechanically coupled to an extension element  502  and a linear encoder  504 . Additionally, the extension element  502  and the linear encoder  504  may also be mechanically coupled to a roller support frame  506  as shown. The position adjustment system  412 , the extension element  502 , and the linear encoder  504  may be used to adjust and/or measure the position or angle of the flange roller  404  as described in greater detail below in connection with  FIG. 9 . 
   In general, the position adjustment system  412  is used in a manufacturing environment to achieve a specified flare tolerance value. Flare is generally associated with the flanges of a formed component such as, for example, the example C-shaped component  200  of  FIG. 2A  and the example Z-shaped component  250  of  FIG. 2B . As described below in connection with  FIGS. 8A and 8B , flare typically occurs at the ends of formed components and may be the result of overforming or underforming. Flare may be measured in degrees by measuring an angle between a flange (e.g., the flange structures  204   a - b  of  FIG. 2A ) and a web (e.g., the web structure  206  of FIG.  2 A). The operating angle of the return or flange roll  404  may be adjusted until, for example, the example C-shaped component  200  has an amount of flare that is within the specified flare tolerance value. 
   The position adjustment system  412  may be implemented using any actuation device capable of actuating the extension element  502 . For example, the position adjustment system  412  may be implemented using a servo motor, a stepper motor, a hydraulic motor, a nut, a hand crank, a pneumatic piston, etc. Additionally, the position adjustment system  412  may be mechanically coupled or integrally formed with a threaded rod that screws or threads into the extension element  502 . In this manner, as the position adjustment system  412  is operated (e.g., turned or rotated), the threaded rod causes the extension element  502  to extend or retract to move the roller support frame  506  to vary the angle of the flange roller  404 . 
   The linear encoder  504  may be used to measure the distance through which the position adjustment system  412  displaces the roller support frame  506 . Additionally or alternatively, the information received from the linear encoder  504  may be used to determine the angle and/or position of the flange roller  404 . In any case, any device capable of measuring a distance associated with the movement of the roller support frame  506  may be used to implement the linear encoder  504 . 
   The linear encoder  504  may be communicatively coupled to an information processing system such as, for example, the example processor system  1510  of  FIG. 15 . After acquiring a measurement, the linear encoder  504  may communicate the measurement to a memory of the example processor system  1510  (e.g., the system memory  1524  or mass storage memory  1525  of  FIG. 15 ). For example, the flange roller  404  may be configured to use one of a plurality of angle settings based on the characteristics of the material being processed. To facilitate the setup or configuration of the example forming unit  400  for a particular material, target settings or measurements associated with the linear encoder  504  may be retrieved from the mass storage memory  1525 . The position adjustment system  412  may then be used to set the position of the roller support frame  504  based on the retrieved target settings or measurements to achieve a desired angle of the flange roller  404 . 
   The position and/or angle of the flange roller  404  may be configured by hand (i.e., manually) or in an automated manner. For example, if the position adjustment system  412  includes a hand crank, an operator may turn or crank the position adjustment system  412  until the target setting(s) acquired by the linear encoder  504  matches or is substantially equal to the measurement retrieved from the mass storage memory  1525 . Alternatively, if a stepper motor or servo motor is used to implement the position adjustment system  412 , the example processor system  1510  may be communicatively coupled to and configured to drive the position adjustment system  412  until the measurement received from the linear encoder  504  matches or is substantially equal to the target setting(s) retrieved from the mass storage memory  1525 . 
   Although, the position adjustment system  412  and the linear encoder  504  are shown as separate units, they may be integrated into a single unit. For example, a servo motor used to implement the position adjustment system  412  may be integrated with a radial encoder that measures the number of revolutions performed by the position adjustment system  412  to displace the roller support frame  506 . Alternatively, the linear encoder  504  may be integrated with a linear actuation device such as a pneumatic piston. In this manner, the linear encoder  504  may acquire a distance or displacement measurement as the pneumatic piston extends to displace the roller support frame  506 . 
     FIG. 6  is an elevational view of the example forming unit  400  of  FIGS. 4A and 4B .  FIG. 6  clearly depicts the mechanical relationships between the flange roller  404 , the position adjustment system  412  of  FIG. 4A , the extension element  502 , the linear encoder  504 , and the roller support frame  506  of  FIG. 5 . When the position adjustment system  412  moves the extension element  502 , the roller support frame  506  is displaced, which causes the flange roller  404  to be tilted or rotated about a pivot point  508  of the flange roller  404 . The pivot point  508  may be defined by the point at which the upper side roll  402   a , the lower side roll  402   b , and the flange roll  404  form a fold or bend. The extension element  502  is extended until the flange roller  404  is positioned at a negative angle as depicted, for example, in a configuration at time to  908   a  of  FIG. 9 . When the position adjustment system  412  retracts the extension element  502  to move the flange roller  404  about the pivot point  508 , the flange roller  404  is positioned at a positive angle as depicted, for example, in a configuration at time t 2    908   c  of  FIG. 9 . 
     FIGS. 7A and 7B  are plan views of example roller assemblies  700  and  750  of a forming unit (e.g., the forming unit  400  of  FIGS. 4A and 4B ). The roller assemblies  700  and  750  correspond to different forming passes of, for example, the example roll-former system  100 . For example, the example roller assembly  700  may correspond to the pass p 4  of  FIG. 3  and the example roller assembly  750  may correspond to the pass p 5  of  FIG. 3 . In particular, the example roller assembly  700  depicts the rollers  402   a - b  and  404  of  FIGS. 4A and 4B  in a configuration for bending or folding a material (i.e., the material  102  of  FIG. 1 ) to form the component profile  304   d  ( FIG. 3 ). The example roller assembly  750  depicts an upper side roller  752   a , a lower side roller  752   b , and a flange roller  754  having a forming surface  756 . The rollers  752   a - b  and  754  may be configured to receive the material  102  from, for example, the example roller assembly  700  and perform a bending or folding operation to form the component profile  304   e  ( FIG. 3 ). 
   As shown in  FIGS. 7A and 7B , the forming surfaces  406  and  756  are configured to form a desired bend in the material  102  ( FIG. 1 ). Forming surfaces of other roller assemblies of the example roll-former system  100  may be configured to have different angles to form any desired bend in the material  102 . Typically, the angles of forming surfaces (e.g., the forming surfaces  406  and  756 ) gradually increase in successive forming passes (e.g., the forming passes  108   a - g  of  FIG. 1 ) so that as the material  102  passes through each of the forming passes  108   a - g , the material  102  is gradually bent or folded to form a desired final profile as described above in connection with  FIG. 3 . 
     FIG. 8A  is an isometric view and  FIGS. 8B and 8C  are plan views of example C-shaped components having underformed ends (i.e., flared-out ends) and/or overformed ends (i.e., flared-in ends). In particular,  FIG. 8A  is an isometric view and  FIG. 8B  is a plan view of an example C-shaped component  800  having underformed ends (i.e., flared-out ends). The example C-shaped component  800  includes return structures  802   a  and  802   b , flange structures  804   a  and  804   b , a web structure  806 , a leading edge  808 , and a trailing edge  810 . In a C-shaped component such as the example C-shaped component  800 , flared ends are typically associated with the flange structures  804   a - b . However, flare may also occur in the return structures  802   a - b.    
   Flare typically occurs at the ends of formed components and may be the result of overforming or underforming, which may be caused by roller positions and/or varying material properties. In particular, spring or yield characteristics of a material (i.e., the material  102  of  FIG. 1A ) may cause the flange structures  804   a - b  to flare out or to be underformed upon exiting a forming pass (e.g., one of the forming passes  108   a - g  of  FIG. 1 ). Overform or flare-in, typically occurs when a formed component (e.g., the example C-shaped component  800 ) travels into a forming pass and forming rolls (e.g., the flange roll  404  of  FIG. 4 ) overform, for example, the flange structures  804   a - b  as the example C-shaped component  800  is aligned with the forming rolls. In general, flare may be measured in degrees by determining the angle between the one or more of the flange structures  804   a - b  and the web structure  806  at both ends of a formed component (i.e., the leading end  808  and trailing end  810 ). 
   As shown in  FIG. 8B , the example C-shaped component  800  includes a leading flare zone  812  and a trailing flare zone  814 . The amount of flare associated with the leading flare zone  812  may be measured as shown in  FIG. 8A  by determining the measurement of a leading flare angle  816 . Similarly, the amount of flare in the trailing flare zone  814  may be measured by determining the measurement of a trailing flare angle  818 . Flare is typically undesirable and needs to be less than or equal to a flare tolerance or specification value. To reduce flare, the angle of the return or flange roll  404  of  FIG. 2A  and/or the return or flange roll  854  of  FIG. 8B  may be adjusted as described below in connection with  FIG. 9 . 
     FIG. 8C  is a plan view of another example C-shaped component  850  having an overformed leading end  852  (i.e., a flared-in end) and an underformed trailing end  854  (i.e., a flared-out end). As shown in  FIG. 8C , flare-in typically occurs along the length of a leading flare zone  856  and flare-out typically occurs at a trailing flare zone  858 . As described above, flare-in may occur when a formed component (e.g., the example C-shaped component  800 ) travels into a forming pass and forming rolls (e.g., the flange roll  404  of  FIG. 4 ) overform, for example, the flange structures  804   a - b  until the example C-shaped component  800  is aligned with the forming rolls. This typically results in a formed component that is substantially similar or identical to the example C-shaped component  850 . Although, the example methods and apparatus described herein are described with respect to the example C-shaped component  800 , it would be obvious to one of ordinary skill in the art that the methods and apparatus may also be applied to the example C-shaped component  850 . 
     FIG. 9  is an example time sequence view  900  depicting the operation of a flange roller (e.g., the flange roller  404  of  FIG. 4B ). In particular, the example time sequence  900  shows the time varying relationship between two rollers  902   a  and  902   b  and a flange roller  904  during operation of the example roll-former system  100  ( FIG. 1 ). As shown in  FIG. 9 , the example time sequence  900  includes a time line  906  and depicts the rollers  902   a - b  and  904  at several times during their operation. More specifically, the rollers  902   a - b  and  904  are depicted in a sequence of configurations indicated by a configuration  908   a  at time t 0 , a configuration  908   b  at time t 1 , and a configuration  908   c  at time t 2 . An angle  910  of the flange roller  904  is adjusted to control the flare of a profiled component (i.e., the example C-shaped component  800  of  FIGS. 8A and 8B ) as a material (e.g., the material  102  of  FIG. 1 ) travels through the rollers  902   a - b  and  904 . The flange roller  904  may be repositioned via, for example, the position adjustment system  412 , the extension element  502 , and the roller support frame  506  as described above in connection with  FIG. 5 . 
   The rollers  902   a - b  and  904  may be used to implement a final forming pass of the example roll-former system  100  ( FIG. 1 ) such as, for example, the forming pass  108   g . The final forming pass  108   g  may be configured to receive the example C-shaped component  800  of  FIGS. 8A and 8B  while the rollers  902   a - b  and  904  are configured as indicated by the configuration at time t 0    908   a . Alternatively, the final forming pass  108   g  may be configured to receive the example C-shaped component  850  of  FIG. 8C . In this case, the roller  902   a  applies an outward force to one of the overformed flanges of the leading flare zone  856 , thus causing the overformed flange to move toward the surface of the flange roller  904  that is positioned at a negative angle as shown by the configuration at time t 0    908   a . In this manner, an overformed flange may be pushed out toward a nominal flange position. 
   After the forming pass  108   g  receives the leading flare zone  812  ( FIG. 8B ) and the example C-shaped component  800  travels through the forming unit  108   g , the flange roller  904  may be repositioned so that the angle  910  is reduced from a negative angle value to a nominal angle value or substantially equal to zero. The flange roller  904  is positioned according to the configuration at time t 1    908   b  when the angle  910  is substantially equal to a nominal angle value or substantially equal to zero. As the example C-shaped component  800  continues to move through the forming process, the trailing flare zone  814  enters the forming pass  108   g  and the flange roller  904  is further repositioned toward a positive angle as shown by the configuration at time t 2    908   c.    
   The position or angle of the flange roller  904  may be measured by the linear encoder  504 , which may provide distance measurements to a processor system such as, for example, the example processor system  1510  of  FIG. 15 . The example processor system  1510  may then control the position adjustment system  412  of  FIGS. 4 through 6 . Although, the flange roller  904  is shown as having a cylindrical forming surface profile, any type of forming profile may be used such as, for example, a tapered profile substantially similar or identical to that depicted in connection with the return or forming roller  404  of  FIGS. 4A and 4B . 
     FIG. 10  depicts an example flare control system  1000  that may be used to control the flare associated with a component (e.g., the C-shaped component  200  of  FIG. 2A  and/or the Z-shaped component  250  of  FIG. 2B ). The example flare control system  1000  may be used to control flare in formed components having any desired profile. However, for purposes of clarity, the example C-shaped component  800  is shown in  FIG. 10 . The example flare control system  1000  may be integrated within the example roll-former system  100  of  FIG. 1  or may be a separate system. For example, if the example flare control system  1000  is integrated within the example roll-former system  100 , it may be implemented using the forming pass  108   g.    
   The example flare control system  1000  includes an operator side flange roller  1002  and a drive side flange roller  1004 . The operator side flange roller  1002  and the drive side flange roller  1004  may be integrated within the example roll-former system  100  ( FIG. 1 ). The flange rollers  1002  and  1004  may be substantially similar or identical to the flange roller  756  of  FIG. 7B  or any other flange roller described herein. As is known, the operator side of the example roll-former system  100  is the side associated with an operator (i.e., a person) running the system. The drive side of the example roll-former system  100  is the side that is typically furthest from the operator or opposite the operator side. 
   The example flare control system  1000  may be configured to tilt, pivot, or otherwise position the drive side flange roller  1004  and the operator side flange roller  1002 , as described above in connection with  FIG. 9 , while the example C-shaped component  800  moves past the rollers  1002  and  1004 . Varying an angle (e.g., the angle  910  of  FIG. 9 ) associated with a position of the flange rollers  1002  and  1004  enables the example flare control system  1000  to control the amount of flare at both ends of the example C-shaped component  800 . For example, as shown in  FIG. 8A , the leading flare angle  816  is smaller than the trailing flare angle  818 . If the flange rollers  1002  and  1004  were held in one position as the example C-shaped component  800  passed through, one of the flanges (e.g., one of the flanges  804   a  and  804   b  of FIG.  8 A) may be underformed or overformed. By tilting or pivoting the flange rollers  1002  and  1004  while the material (e.g., the example C-shaped component  800 ) is moving through the example flare control system  1000 , each of the flanges can be individually conditioned via a different pivot or angle setting and variably conditioned along the length of the corresponding flare zones  812  and  814 . 
   The operator side flange roller  1002  is mechanically coupled to a first linear encoder  1006  and a first position adjustment system  1008  via a first roller support frame  1010 . Similarly, the drive side flange roller  1004  is mechanically coupled to a second linear encoder  1012  and a second position adjustment system  1014  via a second roller support frame  1016 . The linear encoders  1006  and  1012 , the position adjustment systems  1008  and  1014 , and the roller support frames  1010  and  1016  may be substantially similar or identical to the linear encoder  504  ( FIG. 5 ), the position adjustment system  412  ( FIG. 4 ), and the roller support frame  506  ( FIG. 5 ), respectively. Additionally, the position adjustment systems  1008  and  1014  and the linear detectors  1006  and  1012  may be communicatively coupled to a processor system  1018  as shown. The example processor system  1018  may be substantially similar or identical to the example processor system  1510  of  FIG. 15 . 
   The example processor system  1018  may be configured to drive the position adjustment systems  1008  and  1014  and change positions of the flange rollers  1002  and  1004  via the roller support frames  1010  and  1016 . As the roller support frames  1010  and  1016  move, the linear detectors  1006  and  1012  may communicate a displacement value to the example processor system  1018 . The example processor system  1018  may then use the displacement value to drive the flange rollers  1002  and  1004  to appropriate positions (e.g., angles). 
   The example processor system  1018  may also be communicatively coupled to an operator side component sensor  1022   a , and a drive side component sensor  1022   b , an operator side feedback sensor  1024   a , and a drive side feedback sensor  1024   b . The component sensors  1022   a - b  may be used to detect the leading edge  808  of the example C-shaped component  800  as the example C-shaped component  800  moves toward the flange rollers  1002  and  1004  in a direction generally indicated by the arrow  1026 . Additionally, the component sensors  1022   a - b  may be configured to measure an amount of flare associated with, for example, the flange structures  804   a - b  ( FIG. 10 ) in a continuous manner as the example C-shaped component  800  travels through the example flare control system  1000  as described in detail below in connection with the example method of  FIG. 12 . The flare measurements may be communicated to the example processor system  1018 , which may then control the positions (i.e., the angle  910  shown in  FIG. 9 ) of the flange rollers  1002  and  1004  in a continuous manner in response to the flare measurements to reduce, modify, or otherwise control the flare associated with the example C-shaped component  800 . 
   Although the functionality to detect a leading edge and the functionality to measure an amount of flare are shown as integrated in each of the component sensors  1022   a - b , the functionalities may be provided by separate sensors. In other words, the functionality to detect a leading edge may be implemented by a first set of sensors and the functionality to measure an amount of flare may be implemented by a second set of sensors. Additionally, the functionality to detect a leading edge may be implemented by a single sensor. 
   The component sensors  1022   a - b  may be implemented using any sensor suitable for detecting the presence of a formed component such as, for example, the C-shaped component  800  ( FIG. 8 ) and measuring flare of the formed component. In one example, the component sensors  1022   a - b  may be implemented using a spring-loaded sensor having a wheel that contacts (e.g., rides on), for example, the flange structures  804   a - b  ( FIG. 8 ). The spring loaded sensor may include a linear voltage displacement transducer (LVDT) that measures a displacement of the flange structures  804   a - b  in a continuous manner as the example C-shaped component  800  travels through the example flare control system  1000  ( FIG. 10 ). The example processor system  1018  may then determine a flare measurement value based on the displacement measured by the LVDT. Alternatively, the component sensors  1022   a - b  may be implemented using any other sensor that may be configured to measure flare along the length of a formed component (e.g., the example C-shaped component  800 ) as it moves through the example flare control system  1000  such as, for example, an optical sensor, a photodiode, a laser sensor, a proximity sensor, an ultrasonic sensor, etc. 
   The component sensors  1022   a - b  may be configured to alert the example processor system  1018  when the leading edge  808  is detected. The example processor system  1018  may then drive the positions of the flange rollers  1002  and  1004  in response to the alert from the component sensors  1022   a - b . More specifically, the example processor system  1018  may be configured to determine when the leading edge  808  reaches the flange rollers  1002  and  1004  based on a detector to operator side flange roller distance  1028  and a detector to drive side flange roller distance  1030 . For example, the example processor system  1018  may detect when the leading edge  808  reaches the flange rollers  1002  and  1004  based on mathematical calculations and/or a position encoder. 
   Using mathematical calculations, the example processor system  1018  may determine the time (e.g., elapsed time) required for the leading edge  808  to travel from the component sensors  1022   a - b  to the operator side flange roller  1002  and/or the drive side flange roller  1004 . These calculations may be based on information received from the component sensors  1022   a - b , the detector to operator side flange roller distance  1028 , a velocity of the example C-shaped component  800 , and a timer. For example, the component sensors  1022   a - b  may alert the example processor system  1018  that the leading edge  808  has been detected. The example processor system  1018  may then determine the time required for the leading edge  808  to reach the operator side flange roller  1002  by dividing the detector to operator side flange roller distance  1028  by the velocity of the example C-shaped component  800  (i.e., time (seconds)=length (inches)/velocity (inches/seconds)). Using a timer, the example processor system  1018  may then compare the time required for the leading edge to travel from the component sensors  1022   a - b  to the operator side flange roller  1002  to the value of a timer to determine when the leading edge  808  reaches the operator side flange roller  1002 . The time (e.g., elapsed time) required for the leading edge  808  to reach the drive side flange roller  1004  may be determined in the same manner based on the detector to drive side flange roller distance  1030 . 
   In a similar manner, the example processor system  1018  may detect when any location on the example C-shaped component  800  reaches the flange rollers  1002  and  1004 . For example, the example processor system  1018  may determine when the end of the leading flare zone  812  reaches the operator side flange roller  1002  by adding the detector to operator side flange roller distance  1028  to the length of the leading flare zone  812 . 
   Alternatively, determining when any location on the example C-shaped component  800  reaches the flange rollers  1002  and  1004  may be accomplished based on a position encoder (not shown). For example, a position encoder may be placed in contact with the example C-shaped component  800  or a drive mechanism or component associated with driving the C-shaped component towards the flange rollers  1002  and  1004 . As the example C-shaped component  800  moves toward the flange rollers  1002  and  1004 , the position encoder measures the distance traversed by the example C-shaped component  800 . The distance traversed by the example C-shaped component  800  may then be used by the example processor system  1018  to compare to the distances  1028  and  1030  to determine when the leading edge  808  reaches the flange rollers  1002  and  1004 . 
   The feedback sensors  1024   a - b  may be configured to measure an amount of flare of the example C-shaped component  800  as the C-shaped component moves away from the flange rollers  1002  and  1004  in a direction generally indicated by the arrow  1026 . The feedback sensors  1024   a - b  may be implemented using any sensor or detector capable of measuring an amount of flare associated with the example C-shaped component  800 . For example, the feedback sensors  1024   a - b  may be implemented using a machine vision system, a photodiode, a laser sensor, a proximity sensor, an ultrasonic sensor, etc. 
   The feedback sensors  1024   a - b  may be configured to communicate measured flare values to the example processor system  1018 . The example processor system  1018  may then use the measured flare values to adjust the position of the flange rollers  1002  and  1004 . For example, if the measured flare values are greater than a flare tolerance or specification, the positions of the flange rollers  1002  and  1004  may be adjusted to increase the angle  910  shown in the configuration at time t 2    908   c  so that the flare of the next formed component may be reduced to meet the desired flare tolerance or specification. 
     FIG. 11  is a flow diagram depicting an example manner in which the example flare control system  1000  of  FIG. 10  may be configured to control the flare of a formed component (e.g., the example C-shaped component  800  of  FIGS. 8A and 8B ). In general, the example method may control flare in the example C-shaped component  800  by varying the positions of a drive side flange roller (e.g., the drive side flange roller  1004  of  FIG. 10 ) and an operator side flange roller (e.g., the operator side flange roller  1002  of  FIG. 10 ), as described above, in response to the location of the C-shape component  800  within the example flare control system  1000 . 
   Initially, the example method determines if a leading edge (e.g., the leading edge  808  of  FIG. 8 ) is detected (block  1102 ). The detection of the leading edge  808  may be performed by, for example, the component sensors  1022   a - b . The detection of the leading edge  808  may be interrupt driven or polled. If the leading edge  808  is not detected, the example method may remain at block  1102  until the leading edge  808  is detected. If the leading edge  808  is detected at block  1102 , the operator side flange roller  1002  and the drive side flange roller  1004  are adjusted to a first position or respective first positions (block  1104 ). The first positions of the flange rollers  1002  and  1004  may be substantially similar or identical to the position of the flange roller  904  of the configuration at time t 0    908   a  as depicted in  FIG. 9 . However, in some instances the first position of the flange rollers  1002  and  1004  may not be identical to accommodate material variations (i.e., variation in the material being formed) and/or variations in the roll-forming equipment. 
   It is then determined if the end of a leading flare zone (e.g., the leading flare zone  812 ) has reached the operator side flange roller  1002  (block  1106 ). An operation for determining when the end of the leading flare zone  812  reaches the operator side flange roller  1002  may be implemented as described above in connection with  FIG. 10 . If it is determined at block  1106  that the end of the leading flare zone  812  has not reached the operator side flange roller  1002 , the example method may remain at block  1106  until the end of the leading flare zone  812  is detected. However, if the end of the leading flare zone  812  has reached the operator side flange roller  1002 , the operator side flange roller  1002  is adjusted to a second position (block  1108 ). The second position of the operator side flange roller  1002  may be substantially similar or identical to the position of the flange roller  904  of the configuration  908   b  at time t 1  as depicted in  FIG. 9 . 
   The example method then determines if the end of the leading flare zone  812  has reached the drive side flange roller  1004  (block  1110 ). If it is determined at block  1110  that the end of the leading flare zone  812  has not reached the drive side flange roller  1004 , the example method may remain at block  1110  until the end of the leading flare zone  812  is detected. However, if the end of the leading flare zone  812  has reached the drive side flange roller  1004 , the drive side flange roller  1004  is adjusted to a third position (block  1112 ). The third position of the drive side flange roller  1002  may be substantially similar or identical to the position of the flange roller  904  of the configuration  908   b  at time t 1  as depicted in  FIG. 9 . 
   It is then determined if the trailing edge  810  has been detected (block  1114 ). The trailing edge  810  may be detected using, for example, the component sensors  1022   a - b  of  FIG. 10  using a polled and/or interrupt-based method. Detecting the trailing edge  812  may be used to determine if the trailing flare zone  814  is in proximity of the flange rollers  1002  and  1004 . Detecting the trailing edge  810  may be used in combination with, for example, a method associated with a position encoder and a known distance as described above in connection with  FIG. 10  to determine if the trailing flare zone  814  has reached the proximity of the flange rollers  1002  and  1004 . Alternatively, the detection of the leading edge  808  at block  1102  and a distance or length associated with the leading edge  808  and the beginning of the trailing flare zone  814  may be used to determine if the trailing flare zone  814  has reached the proximity of the flange rollers  1002  and  1004 . If it is determined at block  1114  that the trailing edge  810  has not been detected, the example method may remain at block  1114  until the trailing edge  810  is detected. On the other hand, if the trailing edge  810  is detected, it is determined if the start of the trailing flare zone  814  has reached the operator side (block  1116 ). 
   If it is determined that the start of the trailing flare zone  814  has not reached the operator side flange roller  1002 , the example method may remain at block  1116  until the start of the trailing flare zone  814  reaches the operator side flange roller  1002 . If it is determined at block  1116  that the start of the trailing flare zone  814  has reached the operator side flange roller  1002 , the operator side flange roller  1002  is adjusted to a fourth position (block  1118 ). The fourth position of the operator side flange roller  1002  may be substantially similar or identical to the position of the flange roller  904  of the configuration  908   c  at time t 2  as depicted in  FIG. 9 . 
   The example method may then determine if the start of the trailing flare zone  814  has reached the drive side flange roller  1004  (block  1120 ). If the start of the trailing flare zone  814  has not reached the drive side flange roller  1004 , the example method may remain at block  1120  until the start of the trailing flare zone  814  has reached the drive side flange roller  1004 . On the other hand, if the start of the trailing flare zone  814  has reached the drive side flange roller  1004 , the drive side flange roller  1004  is adjusted to a fifth position (block  1122 ). The fifth position of the drive side flange roller  1004  may be substantially similar or identical to the position of the flange roller  904  of the configuration  908   c  at time t 2  as depicted in  FIG. 9 . 
   The example method then determines if the example C-shaped component  800  is clear (block  1124 ). The feedback sensor  1024   a - b  ( FIG. 10 ) may be used to detect if the example C-shaped component  800  is clear. If it is determined at block  1124  that the example C-shaped component  800  is not clear, the example method may remain at block  1124  until the example C-shaped component  800  is clear. If the example C-shaped component  800  is clear, the flange rollers  1002  and  1004  are adjusted to a home position (block  1126 ). The home position may be any position in which the flange rollers  1002  and  1004  can be idle (e.g., the first positions described above in connection with block  1104 ). It is then determined if the last component has been formed (block  1128 ). If the last component has been formed, the process returns or ends. If the last component has not been formed, control is passed back to block  1102 . 
   Flare is typically manifested in a formed component (e.g., the example C-shaped component  800 ) in a gradual or graded manner from a first location on the formed component (e.g., the leading edge  808  shown in  FIG. 8 ) to a second location on the formed component (e.g., the end of the leading flare zone  812  shown in  FIG. 8 ). The positions of the flange rollers  1002  and  1004  may be changed based on various component parameters such as, for example, the gradient of flare in a flare zone (e.g., the leading flare zone  812  and/or the trailing flare zone  814 ), the length of the flare zone, and the velocity of the example C-shaped component  800  ( FIG. 8 ). Additionally, various parameters associated with moving the flange rollers  1002  and  1004  may be varied to accommodate the component parameters such as, for example, a flange roller velocity, a flange roller ramp rate, and a flange roller acceleration. The flange roller velocity may be used to control the velocity at which the flange rollers  1002  and  1004  move from a first position to a second position. 
   For example, the operator side flange roller  1002  may be adjusted gradually over time from a first position at block  1104  to a second position at block  1108  as the example C-shaped component  800  travels through the example flare control system  1000 . The movement of the operator side flange roller  1002  from the first position to the second position may be configured by setting, for example, the flange roller velocity, the flange roller ramp rate, and the flange roller acceleration based on the gradient of the leading flare zone  812  and/or the trailing flare zone  814 , the length of one or both of the flare zones  812  and  814 , and the velocity of the example C-shaped component  800 . As the example C-shaped component  800  travels through the example flare control system  1000  ( FIG. 10 ), the position of the operator side flange roller  1002  may move gradually from a first position to a second position to follow a gradient of flare. 
   More specifically, with respect to the example method of  FIG. 1 , after detecting the leading edge  808 , the position of the operator side flange roller  1002  may be adjusted to a first position (block  1104 ). When the leading edge  808  reaches or is in proximity of the operator side flange roller  1002 , the position of the operator side flange roller  1002  may begin to change or adjust from the first position to a second position and will adjust gradually for an amount of time required for the end of the leading flare zone  812  ( FIG. 8 ) (e.g., time (seconds)=length of the example C-shaped component  800  (inches)/velocity of the example C-shaped component  800  (inches/second)) to reach or to be in proximity to the operator side flange roller  1002 . When the end of the leading flare zone  812  ( FIG. 8 ) reaches or is in proximity to the operator side flange roller  1002  as determined at block  1106 , the operator side flange roller  1002  is at the second position described in connection with block  1108 . It will be apparent to one of ordinary skill in the art that the methods described above for adjusting the operator side flange roller  1002  may be used to adjust the driver side flange roller  1004  and may be used to control flare at any position or location along the length of a formed component such as, for example, the example C-shaped component  800 . 
   The position values (e.g., angle settings) for the flange rollers  1002  and  1004  described in connection with the example method of  FIG. 11  may be determined by moving one or more formed components such as, for example, the example C-shaped component  800  through the example flare control system  1000  and adjusting the positions of the flange rollers  1002  and  1004  until the measured flare is within a flare tolerance specification value. More specifically, the positions may be determined by setting the flange rollers  1002  and  1004  to a position, moving the example C-shaped component  800  or a portion thereof (e.g., one of the flare zones  812  and  814 ) through the example flare control system  1000 , measuring the flare of the example C-shaped component  800 , and re-positioning the flange rollers  1002  and  1004  based on the measured flare. This process may be repeated until the measured flare is within a flare tolerance specification value. Additionally, this process may be performed for any flared portion of the example C-shaped component  800 . 
   The position values (e.g., angle settings) for the flange rollers  1002  and  1004  may be stored in a memory such as, for example, the mass storage memory  1525 . More specifically, the position values may be stored in, for example, a database and retrieved multiple times during operation of the example method. Additionally, a plurality of profiles may be stored for a plurality of material types, thicknesses, etc. that may be used in, for example, the example roll-former system  100  of  FIG. 1 . For example, a plurality of sets of position values may be predetermined for any number of different materials having different material characteristics. Each of the position value sets may then be stored as a profile in a database entry and referenced using material identification information. During execution of the example method of  FIG. 11 , an operator may inform the example processor system  1018  of the material that is being used and the example processor system  1018  may retrieve the profile or position value set associated with the material. 
     FIG. 12  is a flow diagram of an example method of a feedback process for determining the positions (e.g., the angle  910  shown in  FIG. 9 ) of an operator side flange roller (e.g., the operator side flange roller  1002  of  FIG. 10 ) and a drive side flange roller (e.g., the drive side flange roller  1004  of  FIG. 10 ). More specifically, the feedback process may be implemented in connection with the example flare control system  1000  ( FIG. 10 ) by configuring the feedback sensors  1024   a  and  1024   b  ( FIG. 10 ) to measure an amount of flare of a completely formed component (e.g., the example C-shaped component  800  of  FIG. 8 ). The example processing system  1018  ( FIG. 10 ) may then obtain the flare measurements from the feedback sensors  1024   a  and  1024   b  and determine optimal position values for the flange rollers  1002  and  1004  ( FIG. 10 ) (i.e., values for the positions described in connection with blocks  1104 ,  1108 ,  1112 ,  1118  and  1112  of  FIG. 11 ) based on a comparison of the flare measurements of the completed component and a flare tolerance specification value. The feedback process may be repeated based on one or more formed components until optimal position values are attained. Alternatively, the feedback process may be continuously performed during the operation of, for example, the example roll-former system  100  ( FIG. 1 ). In this manner, the feedback system may be used to monitor the quality of the formed components. Additionally, if the characteristics of the material change during operation of the example roll-former system  100 , the feedback system may be used to update the position values for the flange rollers  1002  and  1004  to adaptively vary the position value to achieve a desired flare value (i.e., to meet a flare tolerance or specification). 
   The feedback process may be performed in connection with the example method of  FIG. 11 . Additionally, one of ordinary skill in the art will readily appreciate that the feedback process may be implemented using the operator side feedback sensor  1024   a  and/or the drive side feedback sensor  1024   b . However, for purposes of clarity, the feedback process is described, by way of example, as being based on the operator side feedback sensor  1024   a.    
   Initially, the feedback process determines if the leading edge  808  ( FIG. 8 ) of the example C-shaped component  800  ( FIG. 8 ) has reached the operator side feedback sensor  1024   a  (block  1202 ). The operator side feedback sensor  1024   a  may be used to detect the leading edge  808  and may alert, for example, the example processor system  1018  when the leading edge  808  is detected. If the leading edge  808  has not reached the operator side feedback sensor  1024   a , the feedback process may remain at block  1202  until the leading edge  808  reaches the operator side feedback sensor  1024   a . On the other hand, if the leading edge  808  has reached the operator side feedback sensor  1024   a , the operator side feedback sensor  1024   a  obtains a flare measurement associated with the leading flare zone  812  ( FIG. 8 ) (block  1204 ). For example, the example processor system  1018  may configure the operator side feedback sensor  1024   a  to acquire a flare measurement value (block  1204 ) associated with the leading flare angle  816  ( FIG. 8 ) after the leading edge  808  is detected (block  1202 ). The example processor system  1018  may then obtain and store the flare measurement value and/or the value of the leading flare angle  816 . 
   The feedback process then determines if the beginning of the trailing flare zone  814  has reached the operator side feedback sensor  1024   a  (block  1206 ). If the beginning of the trailing flare zone  814  has not reached the operator side feedback sensor  1024   a , the feedback process may remain at block  1206  until the beginning of the trailing flare zone  814  reaches the operator side feedback sensor  1024   a . However, if the beginning of the trailing flare zone  814  has reached the operator side feedback sensor  1024   a , the example processor system  1018  may configure the operator side feedback sensor  1024   a  to obtain a flare measurement value associated with the trailing flare angle  818  ( FIG. 8 ) of the trailing flare zone  814  (block  1208 ). 
   The flare measurement value of the leading flare zone  812  and the flare measurement value of the trailing flare zone  814  may then be compared to a flare tolerance value to determine if the flare in the example C-shaped component  800  is acceptable (block  1210 ). The flare tolerance value for the leading flare zone  812  may be different from the flare tolerance value for the trailing flare zone  814 . Alternatively, the flare tolerance values may be equal to one another. A flare measurement value is acceptable if it is within the flare tolerance value. More specifically, if the flange structure  804   a  ( FIG. 10 ) is specified to form a 90 degree angle with the web  806  ( FIG. 10 ) and is specified to be within +/−5 degrees, the flare tolerance value is +/−5 degrees. In this case, when the flare measurement values of the leading flare zone  812  and the trailing flare zone  814  are received, they are compared with the +/−5 degrees flare tolerance value. The flare measurement values are acceptable if they are within the flare tolerance value of +/−5 degrees (i.e., 85 degrees&lt;acceptable flare measurement value&lt;95 degrees). 
   If it is decided at block  1210  that one or both of the flare measurement values are not acceptable, the position values of the operator side flange roller  1002  are adjusted (block  1212 ). For example, if the flare measurement value of the leading flare zone  812  is not acceptable, the first position of the operator side flange roller  1002  described in connection with block  1104  of  FIG. 11  is adjusted. Alternatively or additionally, if the flare measurement value of the trailing flare zone  814  is not acceptable, the fourth position of the operator side flange roller  1002  described in connection with block  1118  of  FIG. 11  is adjusted. After one or more of the position values are adjusted, control is passed back to block  1202 . 
   If it is decided at block  1210  that both of the flare measurement values are acceptable, the feedback process may be ended. Alternatively, although not shown, if the feedback process is used in a continuous mode (e.g., a quality control mode), control may be passed back to block  1202  from block  1210  when the flare measurement values are acceptable. 
     FIG. 13  is a flow diagram depicting another example manner in which the example flare control system  1000  of  FIG. 10  may be configured to control the flare of a formed component (e.g., the example C-shaped component  800  shown in  FIG. 8 ). In addition to using the example flare control system  1000  of  FIG. 10  in connection with predetermined positions (e.g., the angle  910  shown in  FIG. 9 ) of the operator side flange roller  1002  ( FIG. 10 ) and the drive side flange roller  1004  ( FIG. 10 ) as described above in connection with the example method of  FIG. 11 , the example flare control system  1000  may also be used in a flange roller position adjustment configuration. In particular, the component sensors  1022   a - b  may be configured to measure an amount of flare associated with, for example, the flange structures  804   a - b  ( FIG. 8 ), as the example C-shaped component  800  travels through the example flare control system  1000 . The example processor system  1018  ( FIG. 10 ) may then cause the position adjustment systems  1008  and  1014  to adjust the positions of the flange rollers  1004  and  1008 , respectively, in response to the flare measurements. As described below, this process may be performed continuously along the length of the example C-shaped component  800 . One of ordinary skill in the art will readily appreciate that the example method of  FIG. 13  may be implemented using the operator side component sensor  1022   a  and/or the drive side component sensor  1022   b . However, for purposes of clarity, the example method of  FIG. 13  is described, by way of example, as being based on the operator side component sensor  1022   a.    
   Initially, the example method determines if the leading edge  808  ( FIG. 8 ) of the example C-shaped component  800  ( FIG. 8 ) has reached the operator side component sensor  1022   a  (block  1302 ). The operator side component sensor  1022   a  may be used to detect the leading edge  808  and may alert, for example, the example processor system  1018  when the leading edge  808  is detected. If the leading edge is not detected (i.e., has not reached the operator side component sensor  1022   a ), the example method may remain at block  1302  until the leading edge is detected. If the leading edge is detected at block  1302 , the operator side component sensor  1022   a  may obtain a flare measurement of, for example, the flange structure  804   a  ( FIG. 8 ) (block  1304 ). The operator side component sensor  1022   a  may be configured to communicate an interrupt or alert to the example processor system  1018  indicating that a flare measurement has been obtained. Alternatively, the example processor system  1018  may poll the operator side component sensor  1022   a  in a continuous manner to read a continuously updated flare measurement value. The example processor system  1018  may alternatively be configured to assert measurement commands to the operator side component sensor  1022   a  so that the operator side component sensor  1022   a  obtains a flare measurement at times determined by the example processor system  1018 . 
   The flare measurement value may then be compared with a flare tolerance specification value to determine if the flare measurement value is acceptable (block  1306 ) as described above in connection with block  1210  of  FIG. 12 . If it is determined at block  1306  that the flare measurement value is acceptable, control is passed back to block  1304 . However, if it is determined that the flare measurement value is not acceptable, the position (e.g., the angle  910  shown in  FIG. 9 ) of the operator side flange roller  1002  is adjusted (block  1306 ). For example, the example processor system  1018  may determine a difference value between the flare measurement value and a flare tolerance specification value and configure the position adjustment system  1008  to change or adjust the position of the operator side flange roller  1002  based on the difference value. The position adjustment system  1008  may then push, bend, and/or otherwise form, for example, the flange structure  804   a  to be within the flare tolerance specification value. 
   It is then determined if the example C-shaped component  800  is clear or has traveled beyond proximity of the operator side component sensor  1022   a  (block  1310 ). If the example C-shaped component  800  is not clear, control is passed back to block  1304 . However, if the example C-shaped component  800  is clear, the example method is stopped. Alternatively, although not shown, if the example C-shaped component  800  is clear, control may be passed back to block  1302  to perform the example method for another formed component. 
   The example methods described above in connection with  FIGS. 11-13  may be implemented in hardware, software, and/or any combination thereof. In particular, the example methods may be implemented in hardware defined by the example flare control system  1000  and/or the example system  1400  of  FIG. 14 . Alternatively, the example method may be implemented by software and executed on a processor system such as, for example, the example processor system  1018  of  FIG. 10 . 
     FIG. 14  is a block diagram of an example system  1400  that may be used to implement the example methods and apparatus described herein. In particular, the example system  1400  may be used in connection with the example flare control system  1000  of  FIG. 10  to adjust the positions of the flange rollers  1002  and  1004  ( FIG. 10 ) in a manner substantially similar or identical to the example method of  FIG. 11 . The example system  1400  may also be used to implement a feedback process substantially similar or identical to the feedback process described in connection with  FIG. 12 . 
   As shown in  FIG. 14 , the example system  1400  includes a component detector  1402 , a component position detector  1404 , a storage interface  1406 , a flange roller adjuster  1408 , a flare sensor interface  1410 , a comparator  1412 , and a flange roller position value modifier  1414 , all of which are communicatively coupled as shown. 
   The component detector interface  1402  and the component position detector  1404  may be configured to work cooperatively to detect a component (e.g., the example C-shaped component  800  of  FIG. 8 ) and the position of the component during, for example, operation of the example flare control system  1000  ( FIG. 10 ). In particular, the component detector interface  1402  may be communicatively coupled to a sensor and/or detector such as, for example, the component sensors  1022   a - b  of  FIG. 10 . The component detector interface  1402  may periodically read (i.e., poll) a detection flag or detection value from the component sensors  1022   a - b  to determine if, for example, the leading edge  808  of the example C-shaped component  800  is in proximity of the component sensors  1022   a - b . Alternatively or additionally, the component detector interface  1402  may be interrupt driven and may configure the component sensors  1022   a - b  to send an interrupt or alert when the example C-shaped component  800  is detected. 
   The component position detector  1404  may be configured to determine the position of the example C-shaped component  800  ( FIG. 8 ). For example, as the example C-shaped component  800  travels through the example flare control system  1000  ( FIG. 10 ), the component position detector  1404  may determine when the end of the leading flare zone  812  ( FIG. 8 ) reaches the flange rollers  1002  and  1004  ( FIG. 10 ). Furthermore, the component position detector  1404  may be used in connection with the blocks  1106 ,  1110 ,  1116 , and  1120  of  FIG. 11  to determine when various portions of the example C-shaped component  800  reach the flange rollers  1002  and  1004 . 
   The component position detector  1404  may be configured to obtain interrupts or alerts from the component detector interface  1402  indicating when the leading edge  808  or the trailing edge  810  of the example C-shaped component  800  is detected. In one example, the component position detector  1404  may retrieve manufacturing values from the storage interface  1406  and determine the position of the example C-shaped component  800  based on the interrupts or alerts from the component detector interface  1402  and the manufacturing values. The manufacturing values may include a velocity of the example C-shaped component  800 , a length of the example C-shaped component  800 , the detector to operator side flange roller distance  1028  ( FIG. 10 ), the detector to drive side flange roller distance  1030  ( FIG. 10 ), and timer values, all of which may be used to determine the time duration required for the leading edge  808  to reach the side flange rollers  1002  and  1004  as described above in connection with  FIG. 10 . 
   The storage interface  1406  may be configured to store data values in a memory such as, for example, the system memory  1524  and the mass storage memory  1525  of  FIG. 15 . Additionally, the storage interface  1406  may be configured to retrieve data values from the memory. For example, as described above, the storage interface  1406  may obtain manufacturing values from the memory and communicate them to the component position detector  1404 . The storage interface  1406  may also be configured to obtain position values for the flange rollers  1002  and  1004  ( FIG. 10 ) and communicate the position values to the flange roller adjuster  1408 . Additionally, the storage interface  1406  may obtain flare tolerance values from the memory and communicate the flare tolerance values to the comparator  1412 . 
   The flange roller adjuster  1408  may be configured to obtain position values from the storage interface  1406  and adjust the position of, for example, the flange rollers  1002  and  1004  ( FIG. 10 ) based on the position values. The flange roller adjuster  1408  may be communicatively coupled to the position adjustment system  1008  ( FIG. 10 ) and the linear encoder  1006  ( FIG. 10 ). The flange roller adjuster  1408  may then drive the position adjustment system  1008  to change the position of the operator side flange roller  1002  and obtain displacement measurement values from the linear encoder  1006  that indicate the distance or angle by which the operator side flange roller  1002  has been adjusted or displaced. The flange roller adjuster  1408  may then communicate the displacement measurement values and the position values to the comparator  1412 . The flange roller adjuster  1408  may then continue to drive or stop the position adjustment system  1008  based on a comparison of the displacement measurement values and the position values. 
   The flare sensor interface  1410  may be communicatively coupled to a flare measurement sensor or device (e.g., the feedback sensors  1024   a  and  1024   b  of FIG.  10 ) and configured to obtain flare measurement values of, for example, the example C-shaped component  800  ( FIG. 8 ). The flare sensor interface  1410  may periodically read (i.e., poll) flare measurement values from the feedback sensors  1024   a  and  1024   b . Alternatively or additionally, the flare sensor interface  1410  may be interrupt driven and may configure the feedback sensors  1024   a  and  1024   b  to send an interrupt or alert when a flare measurement value has been obtained. The flare sensor interface  1410  may then read the flare measurement value from one or both of the feedback sensors  1024   a  and  1024   b  in response to the interrupt or alert. Additionally, the flare sensor interface  1410  may also configure the feedback sensors  1024   a  and  1024   b  to detect the presence or absence of the example C-shaped component  800  as described in connection with block  1124  of  FIG. 11 . 
   The comparator  1412  may be configured to perform comparisons based on values obtained from the storage interface  1406 , the flange roller adjuster  1408 , and the flare sensor interface  1410 . For example, the comparator  1412  may obtain flare measurement values from the flare sensor interface  1410  and flare tolerance values from the storage interface  1406 . The comparator  1412  may then communicate the results of the comparison of the flare measurement values and the flare tolerance values to the flange roller position value modifier  1414 . 
   The flange roller position value modifier  1414  may be configured to modify flange roller position values (e.g., values for the positions described in connection with blocks  1104 ,  1108 ,  1112 ,  1118  and  1122  of  FIG. 11 ) based on the comparison results obtained from the comparator  1412 . For example, if the comparison results obtained from the comparator  1412  indicate that a flare measurement value is greater than or less than the flare tolerance value, the flange roller position may be modified accordingly to change an angle (e.g., the angle  910  of  FIG. 9 ) of, for example, one or both of the flange rollers  1002  and  1004 . 
     FIG. 15  is a block diagram of an example processor system  1510  that may be used to implement the apparatus and methods described herein. As shown in  FIG. 15 , the processor system  1510  includes a processor  1512  that is coupled to an interconnection bus or network  1514 . The processor  1512  includes a register set or register space  1516 , which is depicted in  FIG. 15  as being entirely on-chip, but which could alternatively be located entirely or partially off-chip and directly coupled to the processor  1512  via dedicated electrical connections and/or via the interconnection network or bus  1514 . The processor  1512  may be any suitable processor, processing unit or microprocessor. Although not shown in  FIG. 15 , the system  1510  may be a multi-processor system and, thus, may include one or more additional processors that are identical or similar to the processor  1512  and that are communicatively coupled to the interconnection bus or network  1514 . 
   The processor  1512  of  FIG. 15  is coupled to a chipset  1518 , which includes a memory controller  1520  and an input/output (I/O) controller  1522 . As is well-known, a chipset typically provides I/O and memory management functions as well as a plurality of general purpose and/or special purpose registers, timers, etc. that are accessible or used by one or more processors coupled to the chipset. The memory controller  1520  performs functions that enable the processor  1512  (or processors if there are multiple processors) to access a system memory  1524  and a mass storage memory  1525 . 
   The system memory  1524  may include any desired type of volatile and/or non-volatile memory such as, for example, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, read-only memory (ROM), etc. The mass storage memory  1525  may include any desired type of mass storage device including hard disk drives, optical drives, tape storage devices, etc. 
   The I/O controller  1522  performs functions that enable the processor  1512  to communicate with peripheral input/output (I/O) devices  1526  and  1528  via an I/O bus  1530 . The I/O devices  1526  and  1528  may be any desired type of I/O device such as, for example, a keyboard, a video display or monitor, a mouse, etc. While the memory controller  1520  and the I/O controller  1522  are depicted in  FIG. 15  as separate functional blocks within the chipset  1518 , the functions performed by these blocks may be integrated within a single semiconductor circuit or may be implemented using two or more separate integrated circuits. 
   The methods described herein may be implemented using instructions stored on a computer readable medium that are executed by the processor  1512 . The computer readable medium may include any desired combination of solid state, magnetic and/or optical media implemented using any desired combination of mass storage devices (e.g., disk drive), removable storage devices (e.g., floppy disks, memory cards or sticks, etc.) and/or integrated memory devices (e.g., random access memory, flash memory, etc.). 
   Although certain methods, apparatus, and articles of manufacture have been described herein, the scope of coverage of this patent is not limited thereto. To the contrary, this patent covers all methods, apparatus, and articles of manufacture fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents.