Patent Publication Number: US-2022234090-A1

Title: Tubular joint roll forming machine

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application is a continuation of U.S. patent application Ser. No. 17/149,413, filed on Jan. 14, 2021, the content of which is hereby incorporated by reference in its entirety. 
    
    
     FIELD 
     The present disclosure relates generally to roll forming machines, and in particular, roll forming machines for producing tubular joints. 
     BACKGROUND 
     Roll forming machines may be configured to bend an elongated sheet of material into a desired shape as the sheet moves through a plurality of roller stations arranged along the length of the roll forming machine. At each station, the sheet passes through one or more rollers that bend the sheet to alter its cross-sectional profile. Roll forming machines can be configured to produce elongated features with a variety of different cross-sectional shapes. For example, roll forming can be used to produce parts with open cross-sections, such as a U-shaped channel, as well as parts with closed cross-sections, such as a circular pipe. 
     To break the elongated roll formed components into smaller, separate sections, some roll forming machines can include secondary cutting mechanisms configured to cut the elongated component after the desired cross-sectional shape has been achieved. Cutting mechanisms may also be configured to crimp the end of a component so that it may fit within another part. Further, some roll forming machines can include secondary bending mechanisms configured to bend the elongated component to produce curved features with the desired cross-sectional shapes. 
     SUMMARY 
     To consistently and reliably cut, crimp, or bend roll formed components, existing roll forming machines temporally stop the roll forming process while the cutting, crimping, or bending operations are performed. The repeated starting and stopping of the roll forming machine increases wear on the drivetrain of these traditional roll forming machines. Even briefly stopping the roll forming process also decreases the rate at which parts are produced. 
     The present disclosure relates to a roll forming machine configured to cut, crimp, and bend roll formed tubes without starting and stopping the roll forming process. The present roll forming machine uses a cutting/crimping mechanism and a pleat mechanism that are configured to move with the roll formed tube relative to the primary roll forming components in order to perform cutting/crimping and bending operations continuously. 
     In some embodiments, a roll forming machine may be configured for continuously forming a sheet into a joint section of a tube. The roll forming machine may include a frame having a front end and a back end, a plurality of roller stations arranged longitudinally on the frame between the front end and the back end, and a carriage, which may be slidably secured to the frame. Each rolling station may be configured to move the sheet along the frame from the front end to the back end and to bend the sheet to form the tube. A pleat die assembly may be mounted on the carriage and may be configured to repeatedly engage the tube to form a series of pleats, thereby bending the tube to form the tubular joint section. A crimp die assembly may be mounted on the carriage and may be configured to engage the tube to crimp an end of the joint section and sever the end of the joint tube section from the tube. The carriage may move relative to the frame while the tube is engaged with at least one of the crimp die assembly and the pleat die assembly. 
     In some embodiments, a roll forming machine may be configured to continuously form a sheet of material into a tubular joint at an operational speed. The roll forming machine may include a frame having a first end and a second end, a plurality of roller stations arranged longitudinally on the frame and configured to move the sheet of material along the frame from the first end to the second end and to bend the sheet of material into the tubular joint section, and a carriage slidably secured proximate to the second end of the frame and configured to be selectively moved relative to the frame. A pleat die assembly may be mounted on the carriage, and the pleat die assembly may include a plurality of reciprocating pleat die members. A crimp die assembly may be mounted on the carriage adjacent to the pleat die assembly, and the crimp die assembly may include a plurality of reciprocating crimp die members. A carriage actuator may be configured to generally match the operational speed such that the pleat die assembly and the crimp die assembly are configured to continuously form the sheet of material as the sheet of material moves along the frame from the first end to the second end. 
     Some embodiments may include a method for forming a joint section from a tube that is continuously formed from a sheet of material with a roll forming machine. The method may include steps for continuously advancing the sheet of material through a plurality of roller stations to bend the sheet of material to form the tube, sliding, with a carriage actuator, a carriage longitudinally relative to a frame of the roll forming machine such that the carriage moves with the tube, bending, with a pleat assembly positioned on the carriage, the tube to form the joint section, and severing, with a crimp assembly positioned on the carriage, the joint section from the tube. 
     In some embodiments, a joint module may be configured for forming a joint section from a tube that is formed at an operational speed by a roll forming machine including a frame with a front end and a back end. The joint module may include a carriage positioned proximate the back end of the roll forming machine and configured to move in a longitudinal direction relative to the back end, a pleat dies assembly, and a crimp die assembly. The pleat die assembly may be mounted on the carriage and may be configured to repeatedly engage the tube to form a series of pleats thereby bending the tube to form the joint section. The crimp die assembly may be mounted on the carriage and may be configured to engage the tube to crimp an end of the joint section and to sever the end of the joint section from the tube. The carriage may move relative to the frame while the tube is engaged with at least one of the crimp die assembly and the pleat die assembly. 
     In some embodiments, a method may be configured for forming a joint section from a tube with a joint module, wherein the tube is continuously formed from a sheet of material by a roll forming machine. The method may include receiving, by the joint module, the tube from the roll forming machine as the tube is continuously advanced through the roll forming machine, sliding a carriage longitudinally relative to a frame of the roll forming machine such that the carriage moves with the tube, bending, with a pleat assembly positioned on the carriage, the tube to form the joint section, and severing, with a crimp assembly positioned on the carriage, the joint section from the tube. 
     Various other features, objects, and advantages will be made apparent from the following description taken together with the drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The present disclosure is described with reference to the following Figures. 
         FIG. 1  is a perspective view of an embodiment of a roll forming machine including a joint-forming module with a reciprocating pleat die assembly; 
         FIG. 2  is a detailed perspective view of the roll forming machine and joint module of  FIG. 1 ; 
         FIG. 3  is a side view of the roll forming machine and joint module of  FIG. 2 ; 
         FIG. 4  is a top-down view of the roll forming machine and joint module of  FIG. 3 ; 
         FIG. 5  is a bottom-up view of the roll forming machine and joint module of  FIG. 4 ; 
         FIG. 6  is a perspective view of the joint module of  FIG. 5 ; 
         FIG. 7  is a detailed perspective view of the joint module of  FIG. 6 ; 
         FIG. 8  is another detailed perspective view of the joint module of  FIG. 7 ; 
         FIG. 9  is a front view of the joint module of  FIG. 8 ; 
         FIG. 10  is a side view of the joint module of  FIG. 9 ; 
         FIG. 11  is a top-down view of the joint module of  FIG. 10 ; 
         FIG. 12  is a bottom up view of the joint module of  FIG. 11 ; 
         FIG. 13  is a perspective view of a crimp die assembly from the joint module of  FIG. 12 ; 
         FIG. 14  is another perspective view of the crimp die assembly of  FIG. 13 ; 
         FIG. 15  is a front view of the crimp die assembly of  FIG. 14 ; 
         FIG. 16  is a top-down cross-sectional view of the crimp die assembly of  FIG. 15 ; 
         FIG. 17  is a perspective view of a pleat die assembly from the joint module of  FIG. 12 ; 
         FIG. 18  is another perspective view of the pleat die assembly of  FIG. 17 ; 
         FIG. 19  is a rear view of the pleat die assembly of  FIG. 18 ; 
         FIG. 20  is a front cross-sectional view of the pleat die assembly of  FIG. 19 ; 
         FIG. 21  is a top-down cross-sectional view of the pleat die assembly of  FIG. 20 ; 
         FIG. 22  is a perspective view of another embodiment of a roll forming machine with a joint module; 
         FIG. 23  is a perspective view of the joint module of  FIG. 22 ; 
         FIG. 24  is another perspective view of the joint of  FIG. 23 ; 
         FIG. 25  is a detailed perspective view of the roll forming machine and joint module support frame of  FIG. 22 ; 
         FIG. 26  is a bottom-up cross-sectional view of the joint module on the joint module frame of  FIG. 22 ; 
         FIG. 27  is a detailed perspective view of an adjustment mechanism for the crimp die assembly in the joint module of  FIG. 26 ; 
         FIG. 28  is an embodiment of a roll forming machine including a joint module and an extractor module; 
         FIG. 29  is a detailed perspective view of the extractor module including an extractor and a conveyor of  FIG. 28 ; 
         FIG. 30  is a detailed perspective view of the extractor of  FIG. 29 ; 
         FIG. 31  is a rear view of the extractor of  FIG. 30 ; 
         FIG. 32  is an embodiment of a roll forming machine including a joint module, joint extractor, and tube extractor with a collection table; 
         FIG. 33  is a perspective view of the joint extractor and tube extractor with collection table of  FIG. 32 ; and 
         FIG. 34  is another perspective view of the joint extractor and tube extractor with collection table of  FIG. 33 . 
     
    
    
     DETAILED DESCRIPTION 
     In the present description, certain terms have been used for brevity, clarity and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different methods and assemblies described herein may be used alone. 
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. 
     Unless otherwise specified or limited, the phrases “at least one of A, B, and C,” “one or more of A, B, and C,” and the like, are meant to indicate A, or B, or C, or any combination of A, B, and/or C, including combinations with multiple instances of A, B, and/or C. Likewise, unless otherwise specified or limited, the terms “mounted,” “connected,” “linked,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, unless otherwise specified or limited, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings. 
     As used herein, unless otherwise limited or defined, discussion of particular directions is provided by example only, with regard to particular embodiments or relevant illustrations. For example, discussion of “top,” “front,” “back,” “left” or “right” features is generally intended as a description only of the orientation of such features relative to a reference frame of a particular example or illustration. Correspondingly, for example, a “top” feature may sometimes be disposed below a “bottom” feature (and so on), in some arrangements or embodiments. Additionally, use of the words “first,” “second”, “third,” etc. is not intended to connote priority or importance, but merely to distinguish one of several similar elements or machines from another. 
     Referring now to the figures,  FIG. 1  illustrates an embodiment of a roll forming machine  100  configured to receive a substantially planar sheet of material and bend the sheet into an elongated component through a continuous process at an operational speed. For example, the roll forming machine  100  may be configured to receive an elongated strip of sheet metal and bend it into a pipe, tube, and/or any other elongated shape of closed or open cross-sectional profile. The roll forming machine  100  may include a frame  102  with a plurality of roller stations arranged longitudinally between a front end  106  of the machine  100  and a back end  108  of the machine  100 . The sheet is received by a first one of the roller stations  104  positioned proximate the front end  106 , and then moves sequentially through each of the roller stations  104  as the sheet travels towards the back end  108  of the roll forming machine  100 . At each roller station  104 , the sheet passes through one or more rollers  110  that form the sheet of material to change its cross-sectional shape. As the sheet progresses through the roller stations  104 , the planar sheet is incrementally bent into a desired shape before being discharged from the roll forming machine  100 . In the illustrated embodiments, the roll forming machine  100  is configured to form a tube with a closed cross-sectional profile (e.g., a circular, ellipsoid, or rectangular tube). The roll forming machine  100  includes a shaft  114  that is mounted on the frame  102  by a shaft support  116 , and which extends longitudinally along the length of the frame  102  from the shaft support  116  towards the back end  108  of the machine  100 . The shaft  114  passes through a plurality of roller stations  104  positioned between the shaft support  116  towards the back end  108 . The rollers  110  at these roller stations  104  are configured to bend the sheet around the shaft  114  to form a cross-sectional tube with the shaft  114  extending along the interior of the tube. Mandrels, bushings, or other features, which may be mounted on the shaft  114  and positioned within the tube, may be configured to work with the roller stations  104  to bend the sheet into the desired cross-sectional shape. 
     Some embodiments of a roll forming machine may include secondary systems configured to form tubular joint segments from the elongated tube produced by the roll forming machine. A joint section may be at least one of an angled elbow segment, an offset segment, a short or long non-pleated tube, and any other tube segment that is bent or curved to produce two or three dimensional geometry. As illustrated in  FIGS. 1-5 , for example, a roll forming machine  100  can include a joint module  126  positioned at the back end  108  and configured to further process the tube produced by the machine  100 . After the roll formed tube passes through a final roller station of the roll forming process, continued movement of the sheet of material through the roll forming machine  100  may drive the roll formed tube into at least one of a pleat die assembly  128  and a crimp die assembly  130  of the joint module  126 . The pleat die assembly  128  may be configured to bend the roll formed tube into a joint section by repeatedly pleating the sides of the tube. The crimp die assembly  130  may be configured to crimp one end of the joint section and cut the tube at the crimped end to sever the joint section from the elongated tube. The pleat die assembly  128  and the crimp die assembly  130  may be mounted on a carriage  132  that is slidably secured to the back end  108  of the frame  102 . Using at least one actuator (e.g., carriage actuator  134  in  FIG. 5 ), the carriage  132  may be selectively moved along the longitudinal direction towards and/or away from the back end  108  so that the carriage  132  moves with the elongated tube as it is continuously produced by the roll forming machine  100 . This may be useful, for example, so that the pleat die assembly  128  and the crimp die assembly  130  can be used to continuously produce joint segments without starting and stopping the movement of the sheet of material through the roll forming machine  100  to perform pleating or crimping and cutting operations. 
     Having generally described features of a joint module  126  for a roll forming machine  100 , the details of its components and their structure and features will now be discussed. As illustrated in  FIGS. 6-12 , the carriage  132  may include a base  140  with two rails  142  secured to a lower side of the base  140  and extending outwardly from a front side  144  thereof. The rails  142  may be configured to engage at least one rail support on the frame  102  to slidably secure the joint module  126  to the frame  102 . In the illustrated embodiments, for example, the sliding interface between the rails  142  and the frame  102  allow the joint module  126  to be selectively extended or retracted by sliding away from or towards the back end  108  of the frame  102 . Sliding movement of the joint module  126  may be controlled by a carriage actuator  134 , which may be mounted on at least one of the carriage  132  and the frame  102 . In the illustrated embodiment, the carriage actuator  134  is secured to the frame and is configured to be connected to an actuator coupling feature  146  that is positioned on the lower side of the base  140  between the two rails  142  (see, e.g.,  FIG. 5 ). In some embodiments, other carriage actuator configurations may be included. For example, a carriage actuator may be positioned in a different location on the frame, and/or a carriage actuator may be configured to engage the carriage at a different location. Further still, some embodiments may be configured with a carriage actuator mounted on the joint module and configured to engage a portion of the frame. 
     The upper surface of the base  140  of the carriage  132  may be configured to receive the pleat die assembly  128  and the crimp die assembly  130  so that they are in alignment with the roller stations  104  when the joint module  126  is received on the frame  102 . As illustrated in  FIGS. 1-4 , the shaft  114  may extend past the back end  108  of the frame  102  so that it extends into at least one of the pleat die assembly  128  and the crimp die assembly  130 . Some embodiments of a roll forming machine can be configured so that the shaft may move with the joint module as it moves relative to the frame. For example, the shaft support  116  may be slidably connected to the frame  102  so that the shaft  114  and the shaft support  116  can slide in a forward and backward longitudinal direction on the frame  102 . The rails  142  of the joint module  126  may extend along the length of the frame  102  and be rigidly connected to the shaft support  116 . The ridged connection between the rails  142  and the shaft support  116  effectively fixes the position of the shaft  114  relative to the carriage  132  so that the shaft  114  moves with the carriage  132  as they are moved by the carriage actuator  124  (see, e.g.,  FIG. 5 ). This may be useful, for example, so that a portion of the shaft  114  (and any features or parts positioned on the shaft  114 ) may remain within at least one of the pleat die assembly  128  and the crimp die assembly  130  as the joint module  126  is controlled to form joint segments from the roll formed tube. 
     Many alternative configurations for a movable shaft will be recognized by one of ordinary skill in the art, and such configurations are intended to be within the scope of the present application. For example, a roll forming machine can include a shaft actuator configured to selectively slide at least one of the shaft and the shaft support on the frame independently from the movement of the joint module. 
     As shown in  FIGS. 1-4, 6 and 7 , the crimp die assembly  130  may be positioned proximate the front side  144  of the carriage  132  and can be secured to the base  140  by at least one mounting structure  150  configured to be coupled to the upper surface of the base  140  and a side of the crimp die assembly  130 . Referring now to  FIGS. 13-16 , the crimp die assembly  130  may include a support panel  152  with an aperture  154  extending between a front face and a rear face thereof. The aperture  154  is positioned so that, when the crimp die assembly  130  is mounted on the carriage  132 , the shaft  114  of the roll forming machine  100  may extend through the aperture  154 . A plurality of crimp die members  156  may be slidably secured to the rear face of the support panel  152  around the perimeter of the aperture  154 . The crimp die members  156  may be operatively connected to a control ring  158  that is rotatably secured to the support panel  152  around the aperture  154  and the die members  156 . Rotation of the control ring  158  in a first direction may force the crimp die members  156  to move radially inward into a contracted position, and rotation of the control ring  158  in a second direction may force the crimp die members  156  to move radially outward into an expanded position. 
     In the illustrated embodiments, for example, the upper and lower crimp dies members  156  each include a pin  160  that is received in a corresponding angled slot  162  formed in the control ring  158 . The angled slots  162  are oriented so that rotation of the control ring  158  in a first direction (e.g., counterclockwise when facing the rear face of the support panel  152 ) forces the upper and lower die members  156  to move radially inward towards the aperture  154 , while rotation of the control ring  158  in a second direction (e.g., clockwise when facing the rear face of the support panel  152 ) forces the upper and lower die members  156  to move radially outward away from the aperture  154 . The left and right crimp die members  156  may be connected to at least one of the upper and lower crimp die members  156  by a slotted connection that causes the left and right die members  156  to move radially inward and outward with the upper and lower die members  156 . Many alternative crimp die member movement configurations will be recognized by one of ordinary skill in the art, and such configurations are intended to be within the scope of the present application. 
     With continued reference to  FIGS. 13-17 , each crimp die member  156  may include an inwardly facing crimping face  166  that is generally arc shaped and includes a plurality of ridges extending longitudinally away from the rear surface of the support panel  152 . A crimp die mandrel  168  may be configured to be secured to the shaft  114  so that the crimp die mandrel  168  is received within the aperture  154  of the support panel  152 . As illustrated in  FIG. 16 , the crimp die mandrel  168  is dimensioned to leave a gap  170  between the outer surface of the mandrel  168  and the inner edge of the aperture  154  that is sufficiently large to allow the roll formed tube to pass through the aperture  154  in the gap  170 . This may be useful, for example, to allow sections of the elongated tube to pass through the crimp die assembly  130  without performing a crimping operation. The mandrel  168  may include an outward facing crimping surface  172  that is recessed from the outer surface of the crimp die mandrel  168  and includes a plurality of longitudinal ridges corresponding to the ridges of the crimping faces  166  of the crimp die members  156 . The illustrated crimp die mandrel  168  additionally includes a shearing surface  174  that extends radially between the outer surface and the mandrel crimping surface  172 . When the crimp die mandrel  168  is in alignment with the crimp die assembly  130 , the shearing surface  174  may be substantially planar with the rear face of the support panel  152 , and the mandrel crimping surface  172  may be aligned with the crimp die members  156 . 
     When the crimp die members  156  are in the expanded position, their crimping faces  166  are offset radially outward from the aperture  154  and the gap  170  between the mandrel  168  and the interior wall of the aperture  154  provides a ring-shaped passageway through the support panel  152  (see, e.g.,  FIG. 16 ). This may be useful, for example, so that roll formed tube may move through the crimp die assembly  130  by passing through the aperture  154  in the support panel  152  and the gap between the crimp die members  156  and the crimp die mandrel  168 . As the crimp die members  156  are moved radially inward, the die crimping faces  166  moves past the edge of the aperture  154  so that the die members  156  at least partially cover the gap  170  and seal the passageway. In some embodiments, at least one of the crimp die members  156  may be configured to move far enough radially inward so that at least a portion of the crimp die piece  156  overlaps with the shear surface  174  of the crimp die mandrel  168 , thereby completely sealing the corresponding side of the gap  170  when the crimp die members  156  are in the contracted position. 
     To control the movement of the crimp die members  156  between the contracted position and the expanded position, a joint module may include a crimping actuator configured to selectively rotate the crimp die assembly control ring. Referring now to  FIGS. 6-12 , for example, the joint module  126  may include a crimp actuator  180  that is mounted to a lower surface of the base  140  of the carriage  132  with a mounting bracket  182 . The illustrated crimp actuator  180  is a servo actuator configured to selectively rotate an actuator shaft  184  that extends into the mounting bracket  182 . Some embodiments, however, may be configured with a hydraulic actuator or any other type of actuator. The actuator shaft  184  is operatively connected to the control ring  158  by a bar linkage  186  that extends through a slot  188  formed in the base  140  to an arm  190  that extends radially outward from the control ring  158 . To move the crimp die members  156  into the contracted position, the crimp actuator  180  can be controlled to rotate the actuator shaft  184  a first amount of rotation so that the arm  190  is pulled downward by the bar linkage  186 , thereby rotating the control ring  158  in the first direction and moving the die members  156  radially inwardly. To return the crimp die members  156  to the expanded position, the crimp actuator  180  can be controlled to rotate the actuator shaft  184  a second amount of rotation so that the arm  190  is moved upwardly by the bar linkage  186 , thereby rotating the control ring  158  in the second direction and moving the die members  156  radially outwardly. 
     In the illustrated embodiments, the crimp actuator  180  may be configured to actuate the crimp die members  156  by rotating the crimp actuator shaft  184  in a single direction. The bar linkage  186  may be connected to the actuator shaft  184  such that the actuator shaft  184  can be rotated 360 degrees, and the first amount of rotation and the second amount of rotation are both made in the same direction. In some embodiments, however, the crimp actuator  180  may be configured to actuate the crimp die members  156  by rotating the actuator shaft  184  in a reciprocating fashion. In such an embodiment, the first amount of rotation may be made in a first direction and the second amount of rotation may be made in a second direction opposite the first. 
     As previously mentioned, the crimp die assembly  130  can be used to cut and crimp an end of the elongated tube through selective movement of the crimp die members  156  between the expanded and contracted positions. When the crimp die members  156  move into the contracted position, the sides of the tube are pressed inward towards the outward facing mandrel crimping surface  172  by in crimping faces  166  of the crimp die members  156 . The pressure exerted on the sides of the tube by the crimping faces  166  of the crimp die members  156  creates a shear force between the crimp die members  156  and the outermost surface of the crimp die mandrel  168  at the shear surface  174 , thereby cutting the elongated tube at the shear surface  174  to create a free tube section that is separate from the elongated tube still connected to the sheet of material. Additionally, the inward movement of the crimp die members  156  may crimp the end of the free tube segment by compressing the tube segment wall to reduce the diameter of the free tube segment proximate its newly cut end. This may be useful, for example, so that the crimped end of one tube segment may fit within the diameter of an uncrimped end of another tube segment. After the tube has been cut and crimped with the crimp die assembly  130 , the crimp die members  156  can be moved back to the expanded position so that another length of elongated tube can enter the crimp die assembly  130 . 
     To perform cutting and crimping processes continuously without pausing the roll forming process, the carriage actuator  134  can be controlled to move the carriage  132  away from the back end  108  of the frame  102  at the same speed or a similar speed that the elongated tube is moving through the roller stations  104  when the crimp die members  156  are moved between the expanded and contracted positions. By generally matching the speed of the carriage  132  to the speed of the elongated tube, the crimp die assembly  130  can cleanly cut the elongated tube without distorting the ends of the tube segments while the elongated tube is continuously formed. In the illustrated embodiments, the rigid connection between the rails  142  of the joint module  126  and the shaft support  116  maintains alignment between the crimp die members  156  and the crimp die mandrel  168 . In embodiments where the shaft is independently actuated, however, the shaft and/or shaft support may be controlled to slide towards the back end of the frame at the same rate as the carriage in order to maintain alignment. Once the crimp die members  156  have returned to the expanded position, the carriage may be retracted back towards the back end  108  of the frame  102  before cutting and crimping and additional tube segment. 
     With reference to  FIG. 6 , the pleat die assembly  128  may be positioned on the upper surface of the base  140  proximate the back side  210  of the carriage  132  so that the pleat die assembly  128  is positioned behind the crimp die assembly  130 . Referring now to  FIGS. 17-21 , the pleat die assembly  128  may include a support panel  212  configured to be mounted on the carriage  132 , and including an aperture  214  extending through the support panel  212  from a front face to a rear face thereof. The aperture  214  may be positioned within the support panel  212  so that it is concentric with the aperture  154  formed through the crimp die assembly support panel  152  while the pleat and crimp die assemblies  128 ,  130  are mounted on the carriage  132 . This may be useful, for example, so that the shaft  114  and roll formed tubing that extends through the crimp die assembly  130  may subsequently extend into the passageway through the pleat die assembly. 
     A plurality of pleat die members  220  may be slidably secured to the front face of the support panel  212  around the perimeter of the aperture  214 . The pleat die members  220  may be operatively connected to a control ring  222  that is rotatably secured to the support panel  212  around the aperture  214  and the die members  220 . Rotation of the control ring  222  in a first direction may cause the pleat die members  220  to move radially inwardly into an extended position, and rotation of the control ring  222  in a second direction may cause the pleat die members  220  to move radially outwardly into a retracted position. In the illustrated embodiments, for example, each of the four pleat die members  220  may include a pin  224  position on an arm that extends outwardly from the body of each die member  220 . Each of the pins  224  projects from the arm away from the support panel  212  and is received in a corresponding angled slot  228  formed in the control ring  222 . The angled slots  228  are oriented so that rotation of the control ring  222  in a first direction (counterclockwise when facing the front face of the support panel  212 ) forces the pleat die members  220  to move radially inwardly towards the aperture  214 , while rotation of the control ring  222  in a second direction (clockwise when facing the front face of the support panel  212 ) forces the pleat die members  220  to move radially outwardly away from the aperture  214 . In some embodiments, at least one slot  228  formed in a control ring  222  may have a different shape. For example, a slot may have a curved (i.e., radiused) shape or any other geometric shape. 
     With continued reference to  FIGS. 17-21 , a pleat die mandrel  248  may be mounted on the shaft  114  so that the pleat die mandrel  248  is positioned in alignment with the pleat die members  220 . Each of the pleat die members  220  may include a pleat extrusion  250  the extends radially inward from an inward-facing surface of the pleat die piece  220 . The pleat extrusions  250  are generally arc-shaped and can be configured to be selectively received in a grove  254  formed around the outer surface of the pleat die mandrel  248 . In the illustrated embodiments, the pleat die mandrel  248  and the pleat die members  220  are dimensioned to provide a gap between the pleat die mandrel  248  and the pleat extrusions  250  when the pleat die members  220  are in the retracted position. This may be useful, for example, so that roll formed tube may move through the pleat die assembly  128  by passing through the aperture  214  in the support panel  212  and the gap between the pleat die members  220  and the pleat die mandrel  248 . When the pleat die members  220  are moved into the extended position by the control ring  222 , the pleat extrusions  250  move radially inward into the grove  254  formed around the pleat die mandrel  248 , thereby closing the passageway through the pleat die assembly  128 . If a portion of the roll formed tube is positioned between the pleat die members  220  and the pleat die mandrel  248  as the pleat die members  220  moves into the extended position, the wall of the tube may be deformed as the wall is pressed into grove  254  by the pleat extrusions  250 . This may cause the deformed portion of the wall to fold over itself, thereby forming a pleat in the wall of the elongated tube. 
     To control the movement of the pleat die members  220  between the extended position and the retracted position, a joint module may include a pleat actuator configured to selectively rotate the pleat die assembly control ring. Referring to  FIGS. 6-12 , for example, the joint module  126  may include a pleat actuator  258  that is mounted to a lower surface of the base  140  of the carriage  132  with a mounting bracket  260 . The illustrated pleat actuator  258  is configured as a servo actuator configured to selectively rotate an actuator shaft  262  that extends into the mounting bracket  260 . Some embodiments, however, may be configured with a hydraulic actuator or any other type of actuator. The actuator shaft  262  is operatively connected to the control ring  222  by a bar linkage  264  that extends through a slot  266  formed in the base  140  to an arm  268  that extends radially outward from the control ring  222 . To move the pleat die members  220  into the extended position, the pleat actuator  258  can be controlled to rotate the actuator shaft  262  a first amount of rotation so that the arm  268  is pulled downwardly by the bar linkage  264 , thereby rotating the control ring  222  in the first direction and moving the die members  220  radially inwardly. To return the pleat die members  220  to the retracted position, the pleat actuator  258  can be controlled to rotate the actuator shaft  262  a second amount of rotation so that the arm  268  is moved upwardly by the bar linkage  264 , thereby rotating the control ring  222  in the second direction and moving the die members  220  radially outwardly. 
     In the illustrated embodiments, the pleat actuator  258  may be configured to actuate the pleat die members  220  by rotating the pleat actuator shaft  262  in a single direction. The bar linkage  264  may be connected to the actuator shaft  262  such that the actuator shaft  262  can be rotated 360 degrees, and the first amount of rotation and the second amount of rotation are both made in the same direction. In some embodiments, however, the pleat actuator  258  may be configured to actuate the pleat die members  220  by rotating the actuator shaft  262  in a reciprocating fashion. In such an embodiment, the first amount of rotation may be made in a first direction and the second amount of rotation may be made in a second direction opposite the first. 
     In some embodiments, a pleat die assembly may include a direction control system configured to selectively prevent at least one of the pleat die members  220  from being moved by the control ring  222 . In the illustrated embodiments, for example, the upper and lower pleat die members  220  may be selectively disengaged from the control ring  222 . In addition to engaging an angled slot  228  in the control ring  222 , the pins  224  of upper and lower pleat die members  220  each extend towards the support panel  212  to engage a second angled slot  232  formed in a corresponding selector plate  234  that is slidably received in a recess  236  formed in the front face of the support panel  212 . As illustrated in  FIG. 20 , the selector plates  234  can slide laterally within the respective recess  236 . Pleat engagement actuators  238  secured to a rear face of the support panel  212  and are connected to one of the selector plates  234  through a lateral slot formed through the support panel  212 . The engagement actuators  238  may be configured to independently move plate  234  within the respective recess  236  to disengage one of the pleat die members  220 . When an engagement actuator  238  is controlled to move a plate  234  in a first direction, the interface between the angled slot  232  in the selector plate  234  and the pin  224  forces the corresponding pleat die member  220  to move into a disengaged position by moving the pin  224  radially outwardly and out of the control ring  222  through a notch  244  formed in the side of the control ring  222 . While a pleat die member  220  is in a disengaged position, the control ring  222  can be rotated without moving the disengaged die member  220 . Thus, an elongated tube received in the pleat die assembly  128  may not be pleated on the side of the tube corresponding to a disengages pleat die member  220 . To move the pleat die member  220  back into an engaged position, the selector actuator  238  can be controlled to move the selector plate  234  in a second lateral direction opposite the first direction to force the pin  224  to move back into the corresponding angled slot  228  in the control ring  222  through the notch  244 . 
     As previously discussed, the pleat die assembly  128  may be configured to bend the elongated tube to form a joint section. In some embodiments, the bend may be produced by repeatedly pleating the wall of the elongated tubes on three of four sides at regular intervals along the length of the tube. In the illustrated embodiments, for example, the elongated tube may be bent upwards or downwards by actuating the control ring  222  to extend the pleat die members  220  while the lower pleat die member  220  or the upper pleat die member  220 , respectively, is disengaged from the control ring  222 . When a side of the elongated tube is pressed between the pleat extrusion  250  of a pleat die member  220  and the grove  254  of the pleat die mandrel  248 , the engaged portion of the tube wall is deformed to form a pleat, thereby reducing the overall length of the pleated side of the tube. Asymmetrical pleating of a tube (i.e., pleating on three sides) results in the tube bending away from the unpleated side of the tube, which does not change in length. Each asymmetrical pleat may result in only a relatively small bend in the elongated tube, so, in some embodiments, the tube may be repeatedly pleated at regular intervals along its length until the desired bend angle is obtained. Other embodiments, however, may be configured with an adjustable pleat die assembly that may be adjusted to increase or decrease the bend angle formed by each pleat in the elongated tube. 
     Traditional bending mechanisms for roll forming machines obtain the desired pleat spacing by stopping the roll forming process to perform a pleat, then restarting the roll forming process to advance the elongated feature the desired distance before pausing again to form a subsequent pleat. The illustrated roll forming machine  100 , in contrast, may be configured to perform pleating operations without stopping or reducing the speed of the roll forming process. In some embodiments, the carriage actuator  134  can be configured to move the carriage  132  away from the back end  108  of the frame  102  at the same speed that the elongated tube is moving through the roller stations  104  while the pleat die members  220  are moved between the extended and retracted positions to form a pleat in the elongated tube. After a pleat is formed, the carriage actuator  134  can be controlled to briefly stop or decrease the movement speed of the carriage  132  so that the elongated tube may advance through the pleat die assembly  128  to the location of the next pleat. 
     Additionally, or alternatively, a joint module can include a movable pleat die assembly that is configured to slide laterally on the carriage. As illustrated in  FIGS. 7-12 , for example, the pleat die assembly  128  may be mounted on a slide  272  that is secured to the upper surface of the base  140  of the carriage  132  through a sliding interface. The slide  272  is positioned above a longitudinal slot  274  formed through the base  140 , and a follower pin  278  secured to the bottom of the slide  272  may extend downward through the longitudinal slot  274  to engage a cam  280  mounted on the lower surface of the carriage  132 . The cam  280  and follower pin  278  may be configured so that rotation of the cam  280  causes the pleat assembly  128  to slide forwards and backwards along the longitudinal direction. This may be useful, for example, so that the pleat die assembly  128  can be moved forward to maintain its position relative to the elongated tube while the pleat die members  220  are moved between the extended and retracted positions. Additionally or alternatively, the cam  280  can be configured to move the pleat die assembly  128  towards the front side of the carriage  132  as the pleat die members  220  are moved into the extended position, thereby causing the elongated tube to be pushed into the pleat die members  220  while they are engaged with the sides of the elongated tube. This may be useful to help fold the deformed portions of the tube wall to create the pleat. 
     To link the sliding movement of a pleat die assembly  128  to the actuation of the pleat die members  220 , the cam  280  may be mechanically linked to the pleat actuator  258 . As illustrated in  FIGS. 1-12 , for example, a linkage assembly  282  may be connected to the cam  280  and may operatively connect the cam  280  to the actuator shaft  262 . As the pleat actuator  258  rotates the actuator shaft  262  to move the pleat die members  220  into the extended position, the linkage assembly  282  may substantially simultaneously rotate the cam  280  a first amount of rotation, thereby sliding the slide  272  and the pleat die assembly  128  in a first longitudinal direction (e.g., towards the front of the joint module  126 ). As the pleat actuator  258  rotates the actuator shaft  262  to move the pleat die members  220  back to the retracted position, the linkage assembly  282  may rotate the cam  280  a second amount of rotation to move the slide  272  and the pleat die assembly  128  in a second longitudinal direction and back to the starting position. In the illustrated embodiments, the pleat actuator  258  and the cam  280  may be configured so that the first amount of rotation, and the second amount of rotation of the cam  280  are both made in the same direction. Additionally or alternatively, the pleat actuator  258  can be configured to rotate the cam  280  in a reciprocating manner such that the first amount of rotation is made in a first direction and the second amount of rotation is made in a second direction opposite the first direction. 
     In some embodiments, the actuator shaft may include a section (not shown) that extends through the mounting bracket  260  to engage the linkage assembly  282 . Other embodiments may include a shaft extension  286  or any other mechanical linkage that connects the actuator shaft  262  to the linkage assembly  282 . Further still, a joint module may include a cam that is rotated independently, or the pleat die assembly may be moved by a different actuation mechanism and/or a separate cam actuator. In the illustrated embodiments, the cam  280  is configured as a barrel cam connected to a shaft  262  of the pleat actuator  258 . Other embodiments, however, may include alternative mechanisms for moving the pleat die assembly on the carriage  132 . For example, a pleat actuator may be linked to the slide via a different type of cam and/or through any other type of linkage. 
     To form a tubular joint section using the roll forming machine  100 , sheet metal may be fed into the roller stations  104  on the frame  102 , which may gradually bend the sheet into a hollow, elongated tube. The illustrated roll forming machine  100  is configured to form a circular tube. However, some roll forming machines may be configured to form differently shaped tube, such as an ellipsoid or rectangular tube. As the roll forming machine  100  continues to receive additional lengths of sheet metal, the roll formed tube is extruded from the roller stations  104  proximate the back end  108  of the frame  102  and may travel into the joint module  126 , first passing through the crimp die assembly  130  then moving through the pleat die assembly  128 . After a predetermined length of elongated tube has moved through the pleat die assembly  128 , exiting through the aperture  214  on the support panel  212 , the carriage actuator  134  can be controlled to begin moving the carriage  132  away from the back end  108  of the frame  102 . The carriage actuator  134  can generally match the speed of the elongated tube so that the crimp and pleat die assemblies  128 ,  130  move with the tube, slightly faster than the tube, or slightly slower than the tube based on the required speed to achieve the desired pleat, crimp and/or cut. 
     Once the carriage  132  begins moving with the elongated tube, the pleat die assembly  128  can be controlled to bend the tube with a plurality of pleats. To bend the tube upwardly, the pleat direction selector system can be controlled to move the lower pleat die member  220  into the disengaged position before the pleat actuator  258  is controlled to move the lateral and upper pleat die members  220  into the extended position by rotating the pleat control ring  222 . As the pleat die members  220  engage and deform the upper and lateral sides of the elongated tube, the cam  280  may be rotated to simultaneously slide the pleat die assembly  128  towards the front of the carriage  132 . The sliding movement of the pleat die members  220  while they are engaged with the deforming portions of the tube wall causes the deformed portions to be folded over an adjacent part of the tube wall thereby forming a pleat. The formation of a pleat around the upper and lateral sides on the elongated tube causes the tube to bend upwardly away from the base  140  of the carriage  132 . After the pleat is formed, the pleat actuator  258  is controlled to return the pleat die members  220  to the retracted position, and the cam  280  is rotated to move the pleat die assembly  128  back towards the rear of the carriage  132 . The carriage actuator  134  may then be controlled to adjust movement speed of the carriage  132  to allow the elongated tube to progress a predetermined distance through the joint module  126  before re-matching the speed of the elongated tube. The pleating process can then be repeated to produce additional pleats along the length of the elongated tube, thereby increasing the bend angle of the joint section. 
     After the desired bend angle has been achieved, the joint section can be severed from the elongated tube by the crimp die assembly  130 . Once the crimp die assembly  130  is aligned with a desired endpoint for the joint section, the crimp actuator  180  may be controlled to move the crimp die members  156  from the expanded position to the contracted position while the carriage  134  generally matches the speed of the carriage  132  to the speed of the elongated tube. As they engage the sides of the tube, the crimp die members  156  may shearingly cut the tube walls against the shear surface  174  of the crimp die mandrel  168 . As the joint section is cut away from the elongated tube, the end of the joint section is pressed against the mandrel crimping surface  172  by the crimping faces of the crimp die members  156 . The force applied by the crimp die members  156  may cause the diameter of the end of the joint section to decrease while a ridged corrugation pattern is formed by the corresponding ridges on the crimp die members  156  and the crimp die mandrel  168 . After the end of the joint section has been crimped and severed from the elongated tube, the crimp actuator  180  can be controlled to return the crimp die members  156  to the expanded position so that the completed joint section may be removed from the joint module  126 . The carriage actuator  134  may then be controlled to move the carriage  132  back towards the frame  102  so that another joint section may be formed. 
     Some embodiments of a roll forming machine may include a differently configured joint module. As illustrated in  FIGS. 22-27 , for example, a roll forming machine  300  may include a joint module  326  with a pleat die assembly  328  and a crimp die assembly  330  that are rigidly connected to the base  340  of the carriage  332 . The joint module  326  is slidably supported on a joint module support frame  320 . Sliding support members  322  positioned on the bottom of the carriage  332  are configured to engage support rails  324  that extend longitudinally along opposite sides of joint module support frame  320 . In some embodiments, the joint module support frame  320  is coupled to the frame  302  of the roll forming machine  300  (see, for example,  FIG. 22 ), while other embodiments may include a freestanding joint module support frame  320  that is not connected to the frame of the roll forming machine  302  (see, for example,  FIG. 25 ). 
     Movement of the joint module  326  towards and away from the back end  308  of frame  302  of the roll forming machine  300  may be selectively controlled by a carriage actuator  350  mounted on the frame  302 . Referring to  FIG. 25 , the carriage actuator, which may be positioned on the frame  302 , is configured to selectively rotate a threaded rod  352  that extends along the joint module support frame  320  to a far-side support  354 . A positioning sleeve  358  is received on the threaded rod  352  and is configured to be threadedly engaged with the threaded rod  352 . As illustrated in  FIG. 26 , the positioning sleeve  358  is configured to be received by at least one coupling bracket  360  positioned on the bottom of the base  340  of the carriage  332  of the joint module  326 . Engagement between a positioning member  362  on the positioning sleeve  358  and a pin (not shown) extending through the coupling bracket  360  may restrict rotational motion of the positioning sleeve  358  relative to the threaded rod  352 . The positioning sleeve  358  may further include a follower pin  366  that projects laterally outward from a side of the positioning sleeve  358 . The follower pin  366  is configured to engage a cam  368 , which is mounted on the shaft  348  of the pleat actuator  346  so that the cam  368  rotates with the shaft  348  as the pleat actuator  346  controls movement of the pleat die assembly  328 . In the illustrated embodiments, the cam  368  is configured as a barrel cam connected to a shaft of the pleat actuator  346 . Other embodiments, however, may include alternative mechanisms for moving the carriage relative to the positioning sleeve. For example, a pleat actuator may be connected to a positioning sleeve via a different type of cam and/or through any other type of linkage. Additionally or alternatively, some embodiments can include a cam actuator configured to rotate a cam independently from the actuation of the pleat actuator. 
     When the carriage actuator  350  is controlled to rotate the threaded rod  352  in a first direction, the threaded engagement between the threaded rod  352  and the positioning sleeve  358  may cause the carriage  332  (which is connected to the positioning sleeve  358  via the follower pin  366  and cam  368 ) to slide along the support rails  324  from the back end  308  of frame  302 . When the threaded rod  352  is rotated in a second direction opposite the first direction, the positioning sleeve and the carriage  332  may be forced to slide back towards the back end  308  of frame  302 . 
     Because the carriage  332  is linked to the positioning sleeve  358  through the cam  368 , the joint module  326  may also be selectively moved towards and away from the back end  308  of frame  302  by pleat actuator  346  as it controls the pleat die assembly  328  to pleat an elongated tube. As the cam  368  is rotated, the carriage  332  may slide along the support rails  324 , thereby moving longitudinally relative to the positioning sleeve  358 . Rotation of the cam  368  by a first amount of rotation may move the carriage  332  in a first longitudinal direction relative to the frame  302  and rotation of the cam  368  by a second amount of rotation may move the carriage  332  in a second longitudinal direction relative to the frame  302 . Thus, the carriage  332  may be moved at a first longitudinal speed by the carriage actuator  350  alone, a second longitudinal speed by the pleat actuator  346  and the cam  368 , and/or a third longitudinal speed due to the combined movements of the carriage actuator  350  and the pleat actuator  346  and cam  368 . The longitudinal movement speed of the carriage  332  relative to the back end  308  of the frame  302  may be controlled based on at least one of an actuation speed of the carriage actuator  350 , an actuation speed of the pleat actuator  346 , the size and/or shape of the cam  368 , and any other factor. Using the carriage actuator  350  and/or the pleat actuator  346  and cam  368 , the longitudinal movement speed of the carriage  332  can be adjusted too generally match the longitudinal movement speed of the carriage. This may include moving the carriage  332  at a longitudinal speed that is the same as the longitudinal speed of the tube, slower than the longitudinal speed of the tube, or faster than the longitudinal speed of the tube based on the required speed to impart the desired pleat, crimp, and/or cut into the tube. In some embodiments, the pleat actuator  346  may be configured to rotate in a single direction such that the first and second amounts of rotation of the cam  368  are both made in the same rotational direction. Additionally or alternatively, the pleat actuator  346  can be configured to move the cam  368  in reciprocating motion such that the first amount of rotation is in a first direction and the second amount of rotation is in a second direction. 
     As with the embodiments of  FIGS. 1-21 , the carriage  332  may be rigidly connected to the shaft support and the shaft of the roll forming machine  300  so that the crimp die mandrel and the pleat die mandrel (which are secured to the shaft) move with the joint module  326  as it moves relative to the back end  308  of frame  302 . This may be useful, for example, so that the pleat die assembly  328  may be moved longitudinally during the pleating process while alignment is maintained between the pleat die members  220  and the pleat die mandrel  248 . 
     Some embodiments of a joint module for a roll forming machine may be configured with at least one of an adjustable pleat die assembly and an adjustable crimp die assembly. For example, as illustrated in  FIGS. 23, 24 and 27 , the pleat die assembly  328  and the crimp die assembly  330  may include an adjustable bar linkage  378 ,  380  that extends through a corresponding slot  382  formed in the base  340  of the carriage  332  to respectively connect the crimp actuator  344  to the arm  384  extending from the crimp control ring  386  and the pleat actuator  346  to the arm  388  extending from the pleat control ring  390 . Each of the adjustable bar linkages  378 ,  380  includes a turnbuckle  392  that may be adjusted to increase or decrease the length of the bar linkage  378 ,  380 . When a turnbuckle  392  is adjusted to increase the length of one of the bar linkages  378 ,  380 , the connected arm  384 ,  388  is pushed upward, thereby rotating the crimp control ring  386  or the pleat control ring  390  and respectively moving the crimp die members or the pleat die members radially inward. Adjusting the turnbuckles  392  to decrease the length of the bar linkages  378 ,  380  causes the crimp die members and the pleat die members to move radially outwardly without using the crimp actuator  344  or the pleat actuator  346 . 
     The illustrated adjustment systems may be useful, for example, to adjust the expanded and contracted radial positions of the crimp die members and/or the extended and retracted radial positions of the pleat die members. The bend angle of a pleated joint section may be controlled based on the radial positions of the pleat die members. Moving the pleat die members radially inward may increase the bend angle of each pleat, while moving the pleat die members radially outward may decrease the bend angle of each pleat. This may be useful, for example, to control the bend angle of the joint section without changing the number of pleats used to form the joint section. Adjustment of the crimp die members may control the diameter of the crimped portion of a joint section. Moving the crimp die members radially outward may increase the diameter of the crimped portion of the joint, while moving the crimp die members radially inward may decrease the diameter of the crimped section. Because the crimp die members and the pleat die members are collectively controlled by the crimp control ring  386  or the pleat control ring  390 , respectively, the adjustable bar linkages  378 ,  380  allow a user to modify the positions of all of the crimp die members or all of the pleat die members simultaneously by making a single adjustment to one of the turnbuckles  392 . 
     While the illustrated adjustable bar linkages  378 ,  380  include a turnbuckle for adjusting their lengths, some embodiments can be configured with a different mechanism for changing the length of a bar linkage. Additionally or alternatively, at least one of the crimp die assembly and the pleat die assembly may be configured with a different mechanism for adjusting the radial positions of the respective die members. Further still, some embodiments may include an adjustment mechanism for independently adjusting the position of at least one of the crimp die members and/or at least one of the pleat die members. 
     In order to measure the positions of the crimp die members and/or the pleat die members, some embodiments of the joint module may include a laser measurement system. As illustrated in  FIGS. 23, 24 and 27 , the pleat die assembly  328  and the crimp die assembly  330  may include a laser sensor  394  that is connected to one of the mounting structures  398  by an positioning member  396  such that the laser sensor  394  is positioned over one of the arms  384 ,  388  extending from the crimp control ring  386  or the pleat control ring  390 . Each of the laser sensors  394  can be configured to measure the distance between the laser sensor  394  and the corresponding arm  384 ,  388 , and the measured distance can then be used to determine the radial positions of the corresponding crimp or pleat die members without manually measuring the die member positions. Using the data generated based on the laser sensor  294  measurements, a user can adjust the positions of the crimp die members and/or the pleat die members by increasing the length of the corresponding adjustable bar linkage  378 ,  380  (thereby decreasing the distance between the laser sensor and arm  384 ,  388 ) or decreasing the length of the corresponding adjustable bar linkage  378 ,  380  (thereby increasing the distance between the laser sensor and arm  384 ,  388 ). 
     In some embodiments of a joint module, at least one of the pleat die assembly and the crimp die assembly can be configured with a different system for determining the positions of the crimp die members and/or the pleat die members. For example, at least one of the laser sensors may be connected to a different part of the joint module, and at least one laser sensor may be configured to measure the position of a different part of the crimp or pleat die assembly. Some embodiments may include at least one different type of sensor configured to measure the position of one of the arms, or to measure a different dimension in order to determine the positions of the crimp or pleat die members. Further still, at least one of the crimp die assembly or the pleat die assembly may be configured without an adjustable bar linkage and/or a laser measurement system. 
     Some embodiments of a roll forming machine can include an extraction system configured to remove a roll formed tube or joint from the roll forming system. As illustrated in  FIG. 28 , for example, a roll forming machine  400  can include an extractor module  410  configured to remove a completed joint section of tube from the joint module  404  after completion. The ejector module may include an extractor  414  configured to pull the joint section away from the joint module  404  and a conveyor  416  configured to transport the joint section. 
     Referring to  FIGS. 29-31 , the extractor  414  may include an extractor carriage  420  slidably mounted on an extractor frame  422 . Linear actuators  424  may be selectively controlled to slide the extractor carriage  420  along rails  426  extending between the front side and the back side of the extractor frame  422 . The extractor  414  includes jaws  430  positioned on opposite sides of an opening  432  that is formed through the extractor carriage  420 . In the illustrated embodiments, the extractor  414  includes two jaws positioned on opposite lateral sides of the opening  432 . Some embodiments, however, may include at least one additional jaw, and at least one jaw may be differently positioned than the illustrated jaws. 
     A jaw actuator  434 , which may be connected to the jaws  430  by a bar linkage assembly  436 , is configured to selectively slide the jaws  430  between a retracted position and an extended position. In the retracted position (see, for example  FIGS. 29-31 ), the jaws  430  may be positioned proximate the edge of the opening  432  so that a roll formed tubular joint section may be received through the opening  432 . As they are move towards their extended positions, the jaws  430  slide inward towards each other and the middle of the opening  432 . When a portion of a joint section (or a straight roll formed tube) is positioned within the opening  432 , the jaws  430  may be configured to grip the joint section so that is supported on the extractor carriage  420 . As the jaws  430  are returned to their retracted positions, any roll formed tube or joint may be released and dropped from the extractor carriage  420 . 
     When used to remove a completed joint section of tube from the joint module  404 , the linear actuators  424  may be configured to move the extractor carriage  420  towards the front of the extractor frame  422  to await completion of the pleating, crimping, and cutting processes of the joint module  404 . As the joint section is formed, it may extend out of the end of the joint module  404  and enter into the opening  432  in the extractor carriage  420 . Once the joint section is positioned within the opening  432 , the jaws  430  can be controlled to move to their extended positions to grip the joint section before it is cut away from the elongated tube still moving through the roll forming machine  400 . Once the joint section is severed from the elongated tube by the crimp die on the joint module  404 , the linear actuators  424  may slide the extractor carriage  420  back towards the rear of the extractor frame  422 , thereby moving the joint section away from the joint module  404  and towards the conveyor  416 . When the extractor carriage  420  reaches the back side of the extractor frame  422 , the jaws  430  can be controlled to return to their retracted positions in order to deposit the joint section on the conveyor  416 . 
     Many alternative configurations for an ejector module will be recognized by one of ordinary skill in the art, and such configurations are intended to be within the scope of the present application. For example, a roll forming machine may include an extractor that is integrated with an elbow module. Additionally or alternatively, some embodiments of an ejector module may be configured without a conveyor system. 
     Referring now to  FIG. 32 , another embodiment of a roll forming machine  500  including a joint module  504 , an extractor module  508  and an enclosure  512  is illustrated. The enclosure  512  include a plurality of enclosure walls  516  positioned around the edges of the frame  518  of the roll forming machine  500  to enclose at least one of the roller stations  520 , the joint module  504  and/or the extractor module  508 . In order to provide a clear view of the roll forming machine  500 , the wire mesh that forms the illustrated enclosure walls  516  has only been included on one side of the roll forming machine  500  in  FIG. 32 . It should be appreciated that wire mesh enclosure walls may additionally or alternatively be provided on at least one other side of the machine. This may be useful, for example, to prevent unauthorized or incidental insertion of an object into the roll forming machine  500 . At least one of the walls  516  may be configured as an openable wall  522  that can be moved from a closed position to an open position to provide access to the roll forming machine  500  when desired. While the illustrated enclosure walls  516 ,  522  are formed from a wire mesh, other embodiments may include walls formed from a different material, such as plexiglass or any other material. Additionally or alternatively, some embodiments may include a jib  524  that extends laterally across the frame  518  from a left side to a right side thereof. The jib  524  may be connected to a lift system (for example, a pulley or other lifting mechanism), and can be used to move components onto or off of the roll forming machine  500 . 
       FIGS. 33 and 34  illustrate an embodiment of an extractor module  508  that may be used with the roll forming machine  500  of  FIG. 32 , or any other embodiment of a roll forming machine. Similarly to the extractor module of  FIGS. 28-31 , the extractor module  508  may include an extractor  530  with retractable jaws  532  configured to grip a joint segment, pull it away from the joint module, and deposit the joint segment on a conveyor system  534 . The conveyor system  534  of the illustrated embodiment, however, is configured to convey a joint segment laterally relative to the frame  518  so that the joint section can be received through an opening  536  formed in the side of the enclosure  512  (see  FIG. 32 ). Additionally or alternatively, the extractor module  508  can include a roller assembly  540  secured to the extractor frame  538  such that it is in alignment with the extractor  530 . When the roll forming machine is used to produce an elongated tube or joint section, the completed tubular section may extend through the jaws  532  of the extractor  530  and into the roller assembly  540 . At least one roller  542  may be moved into engagement with the elongated tube or joint section, and may be powered to move the tubular section longitudinally away from the joint module and onto a receiving rack  544 . Some embodiments may include at least one positionable guide  546  to guide the elongated tube or joint section as it is moved onto the receiving rack  544 . 
     It is to be appreciated that features depicted in conjunction with any one of the illustrated embodiments may be used in conjunction with the features of any other embodiment of the invention. In the above description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different systems described herein may be used alone or in combination with other systems. It is to be expected that various equivalents, alternatives and modifications are possible within the scope of the appended claims. 
     This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.