Patent Publication Number: US-7901526-B2

Title: Window component stock transferring

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     The following patent application is a divisional application that claims priority to U.S. application Ser. No. 11/084,929 filed on Mar. 21, 2005, now U.S. Pat. No. 7,445,682 and further claims priority from provisional U.S. patent application 60/614,454 having a filing date of Sep. 29, 2004. Both applications are incorporated herein by reference in their entireties for all purposes. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to insulating glass units and more particularly to a method and apparatus for transferring elongated window component stock from one station to another station in an elongated window component production line. 
     BACKGROUND OF THE INVENTION 
     Insulating glass units (IGUs) are used in windows to reduce heat loss from building interiors during cold weather. IGUs are typically formed by a spacer assembly sandwiched between glass lites. A spacer assembly usually comprises a frame structure extending peripherally about the unit, a sealant material adhered both to the glass lites and the frame structure, and a desiccant for absorbing atmospheric moisture within the unit. The margins or the glass lites are flush with or extend slightly outwardly from the spacer assembly. The sealant extends continuously about the frame structure periphery and its opposite sides so that the space within the IGUs is hermetic. 
     There have been numerous proposals for constructing IGUs. One type of IGU was constructed from an elongated corrugated sheet metal strip-like frame embedded in a body of hot melt sealant material. Desiccant was also embedded in the sealant. The resulting composite spacer was packaged for transport and storage by coiling it into drum-like containers. When fabricating an IGU the composite spacer was partially uncoiled and cut to length. The spacer was then bent into a rectangular shape and sandwiched between conforming glass lites. 
     Perhaps the most successful IGU construction has employed tubular, roll formed aluminum or steel frame elements connected at their ends to form a square or rectangular spacer frame. The frame sides and corners were covered with sealant (e.g., a hot melt material) for securing the frame to the glass lites. The sealant provided a barrier between atmospheric air and the IGU interior which blocked entry of atmospheric water vapor. Particulate desiccant deposited inside the tubular frame elements communicated with air trapped in the IGU interior to remove the entrapped airborne water vapor and thus preclude its condensation within the unit. Thus after the water vapor entrapped in the IGU was removed internal condensation only occurred when the unit failed. 
     In some cases the sheet metal was roll formed into a continuous tube, with desiccant inserted, and fed to cutting stations where “V” shaped notches were cut in the tube at corner locations. The tube was then cut to length and bent into an appropriate frame shape. The continuous spacer frame, with an appropriate sealant in place, was then assembled in an IGU. 
     Alternatively, individual roll formed spacer frame tubes were cut to length and “corner keys” were inserted between adjacent frame element ends to form the corners. In some constructions the corner keys were foldable so that the sealant could be extruded onto the frame sides as the frame moved linearly past a sealant extrusion station. The frame was then folded to a rectangular configuration with the sealant in place on the opposite sides. The spacer assembly thus formed was placed between glass lites and the IGU assembly completed. 
     IGUs have failed because atmospheric water vapor infiltrated the sealant barrier. Infiltration tended to occur at the frame corners because the opposite frame sides were at least partly discontinuous there. For example, frames where the corners were formed by cutting “V” shaped notches at corner locations in a single long tube. The notches enabled bending the tube to form mitered corner joints; but afterwards potential infiltration paths extended along the corner parting lines substantially across the opposite frame faces at each corner. 
     Likewise in IGUs employing corner keys, potential infiltration paths were formed by the junctures of the keys and frame elements. Furthermore, when such frames were folded into their final forms with sealant applied, the amount of sealant at the frame corners tended to be less than the amount deposited along the frame sides. Reduced sealant at the frame corners tended to cause vapor leakage paths. 
     In all these proposals the frame elements had to be cut to length in one way or another and, in the case of frames connected together by corner keys, the keys were installed before applying the sealant. These were all manual operations which limited production rates. Accordingly, fabricating IGUs from these frames entailed generating appreciable amounts of scrap and performing inefficient manual operations. 
     In spacer frame constructions where the roll forming occurred immediately before the spacer assembly was completed, sawing, desiccant filling and frame element end plugging operations had to be performed by hand which greatly slowed production of units. 
     U.S. Pat. No. 5,361,476 to Leopold discloses a method and apparatus for making IGUs wherein a thin flat strip of sheet material is continuously formed into a channel shaped spacer frame having corner structures and end structures, the spacer thus formed is cut off, sealant and desiccant are applied and the assemblage is bent to form a spacer assembly. 
     SUMMARY 
     The present application concerns a method and apparatus for transferring elongated window component stock from one station to another station in an elongated window component, production line. An apparatus for automatic feeding of elongated sheet stock from a stamping station into a roll forming station in a window component production line includes a transfer mechanism, a feed mechanism and a controller. The transfer mechanism is between the stamping station and the roll forming station. The feed mechanism is positioned at an entrance to the roll forming station. The controller is in communication with the stamping station, the transfer mechanism and the feed mechanism. The controller is programmed to engage stock material that extends from the stamping station with the transfer mechanism, transfer the stock material paid out by the stamping station to the feed mechanism, and drive the feed mechanism to feed the elongated sheet stock into the roll forming station. 
     In one embodiment, the stamping station and the roll forming station are controlled by the controller to create slack in the stock between the stamping station and the roll forming station that causes the stock to droop a predetermined distance. In one embodiment, the controller monitors a width of elongated sheet stock supplied by a stock supply station and automatically adjusts the stamping station to accept sheet stock of the monitored width and adjusts the roll forming station to accept sheet stock of the monitored width. 
     In one embodiment, the transfer assembly comprises a pair of gripping members and a conveyor for moving the pair of gripping members from a first position where the gripping members grip an end portion of the elongated sheet stock to a second position where the gripping members provide the end portion to the feed mechanism. In one embodiment, the transfer assembly comprises a bridge that supports the stock material as the stock material is transferred to the feed mechanism and allows the stock to droop once the stock is engaged by the feed mechanism. In one embodiment, the transfer assembly defines a path of travel between the stamping station and the roll forming station that includes a droop. 
     In one embodiment, the feed mechanism comprises a pair of drive rollers positioned at an entrance to the roll forming station that are selectively moveable between a disengaged position and an engaged position. 
     In a method of feeding elongated sheet stock from a stamping station into a roll forming station in a window component production line, stock material that extends from an outlet of the stamping station is detected. The stock material is automatically transferred from the stamping station to the roll forming station. The elongated sheet stock is fed into the roll forming station. The stamping station and the roll forming station are controlled such that the stock material droops between the stamping station and the roll forming station. 
     The disclosed system has significant advantages over the system disclosed in U.S. Pat. No. 5,361,476 to Leopold. In that system an entire first spacer frame unit was scrapped each time a new roll was threaded into the system. That first frame was only scrapped, however, after dessicant and adhesive were applied to the frame resulting in waste in both time and materials. The disclosed system avoids excess waste by use of a short piece of scrap frame material that is removed from the system conveyor prior to the dessicant application station. 
     The &#39;476 patent has a single supply of strip mounted at the beginning of the frame fabrication system. The present system utilizes an automated strip changeover system. Whereas the prior system might take up to 15 minutes to switch in a new roll of strip material once a preceding strip has been exhausted, the present system achieves changeover in less than one minute. Additionally the reliance on operators for changeover increased the possibility in operator error in set up that is avoided by the disclosed system. 
     The rapid changeover from one roll of strip material to a next roll and the ability to rapidly switch to different width strip material has resulted in efficiencies not achievable in the prior art. In the prior art, the fact that a whole roll of spacer material was used before a change meant that window construction was dependent on receipt of a large batch of frames of a given width. This placed constraints on subsequent manufacturing processes that could be performed and these constraints were not necessarily convenient or compatible with a desire to most efficiently fill customer orders. Use of the presently disclosed system allows rapid changeover from one width strip to a next so that repair units for example can be built as needed to replace damaged window units as they occur. The system produces less work in process and real time response to customer orders in a way that increases total manufacturing throughput. 
     Further features and advantages will become apparent from the following detailed description with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is perspective view of an insulating glass unit; 
         FIG. 2  is a cross sectional view seen approximately from the plane indicated by the line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is a fragmentary plan view of a spacer frame element before the element has had sealant applied and in an unfolded condition; 
         FIG. 4  is a fragmentary elevational view of the element of  FIG. 3 ; 
         FIG. 5  is an enlarged elevational view seen approximately from the plane indicated by the line  5 - 5  of  FIG. 4 ; 
         FIG. 6  is a fragmentary elevational view of a spacer frame forming part of the unit of  FIG. 1  which is illustrated in a partially constructed condition; 
         FIG. 7  is an elevational view of a spacer assembly production line constructed according to the invention; 
         FIG. 8  is a plan view of the production line of  FIG. 7 ; 
         FIG. 9  is a perspective view of a stock supply station; 
         FIG. 10  is a side elevational view of a stock supply station; 
         FIG. 11  is a front elevational view of a stock supply station; 
         FIG. 12  is a top plan view of a stock supply station; 
         FIG. 12A  is a top plan view of an alternate stock supply station; 
         FIG. 13A  is an enlarged view as indicated by reference  FIG. 13  in  FIG. 10 ; 
         FIG. 13B  is an enlarged view as indicated by reference  FIG. 13  in  FIG. 10 ; 
         FIG. 14  is an enlarged view as indicated by reference  FIG. 14  in  FIG. 10 ; 
         FIG. 15  is an enlarged view as indicated by reference  FIG. 15  in  FIG. 10 ; 
         FIG. 16  is a view taken along lines  16 - 16  in  FIG. 15 ; 
         FIG. 17  is a perspective view of the clamping mechanism shown in  FIG. 16 ; 
         FIG. 18  is a perspective view of a stamping station; 
         FIG. 19  is a perspective view of a stamping station; 
         FIG. 20  is a perspective view of a stamping station entrance; 
         FIG. 21  is a side elevational view of a portion of a stamping station; 
         FIG. 22  is a view taken along the plane indicated by lines  22 - 22  in  FIG. 21 ; 
         FIG. 23  is a side elevational view of a transfer mechanism that transfers sheet stock from a stamping station to a roll forming station; 
         FIG. 24  is a side elevational view of sheet stock extending from a stamping station to a roll forming station; 
         FIG. 25  is a perspective view of a transfer mechanism; 
         FIG. 26  is a side elevational view of a transfer mechanism; 
         FIG. 27  is a top plan view of a transfer mechanism; 
         FIG. 28  is an illustration of a transfer mechanism of an alternate embodiment; 
         FIG. 29  is an illustration of a transfer mechanism of an alternate embodiment; 
         FIG. 30  is a perspective view of a roll forming station; 
         FIG. 31  is a side elevational view of a roll forming station; 
         FIG. 32  is a side elevational view of a, roll forming station; 
         FIG. 32A  is an enlarged perspective view of the  FIG. 30  roll forming station depicting a chain tensioner; 
         FIG. 33  is a top plan view of a roll forming station; 
         FIG. 34  is a perspective view of a swedging and cutoff station; 
         FIG. 35  is a view taken along lines  35 - 35  in  FIG. 34 ; 
         FIG. 36  is a view taken along lines  36 - 36  in  FIG. 35 ; 
         FIGS. 36A ,  36 B and  36 C are enlarged perspective views of portions of the swedging station with parts removed for ease of illustration; 
         FIG. 37  is a view taken along lines  37 - 37  in  FIG. 36 ; 
         FIG. 38  is a side elevational view of a cutoff station; 
         FIG. 39  is a partial perspective view of a conveyor; 
         FIG. 40  is a partial top plan view of the conveyor shown in  FIG. 39 ; 
         FIG. 41  is a partial side elevational view of the conveyor shown in  FIG. 39 ; 
         FIG. 42  is a perspective view of a conveyor; 
         FIG. 43  is a partial perspective view of a conveyor showing a scrap removal apparatus; 
         FIG. 44  is a partial side elevational view of a conveyor showing a scrap removal apparatus; 
         FIG. 45  is a schematic representation of a scrap removal apparatus; 
         FIG. 46  is a schematic representation of a scrap removal apparatus; 
         FIG. 47  is a schematic representation of a scrap removal apparatus; 
         FIG. 48  is a partial perspective view of a conveyor showing an alternate scrap removal apparatus; 
         FIG. 49  is an enlarged perspective view of the alternate scrap removal apparatus of  FIG. 48 ; and 
         FIG. 50  is an enlarged perspective view of the alternate scrap removal apparatus of  FIG. 48  with a pusher mechanism actuated for removing scrap from the conveyor. 
     
    
    
     DETAILED DESCRIPTION 
     The drawing Figures and following specification disclose a method and apparatus for producing elongated window components  8  used in insulating glass units. Examples of elongated window components include spacer assemblies  12  and muntin bars  130  that form parts of insulating glass units. The new method and apparatus are embodied in a production line which forms sheet metal ribbon-like stock material into muntin bars and/or spacers carrying sealant and desiccant for completing the construction of insulating glass units. While the elongated window components illustrated as being produced by the disclosed method and apparatus are spacers, the claimed method and apparatus may be used to produce any type of elongated window component, including muntin bars. 
     The Insulating Glass Unit 
     An insulating glass unit  10  constructed using the method and apparatus of the present invention is illustrated by  FIGS. 1-6  as comprising a spacer assembly  12  sandwiched between glass sheets, or lites,  14 . The assembly  12  comprises a frame structure  16 , sealant material  18  for hermetically joining the frame to the lites to form a closed space  20  within the unit  10  and a body  22  of desiccant in the space  20 . See Figure The unit  10  is illustrated in  FIG. 1  as in condition for final assembly into a window or door frame, not illustrated, for ultimate installation in a building. The unit  10  illustrated in  FIG. 1  includes muntin bars  130  that provide the appearance of individual window panes. 
     The assembly  12  maintains the lites  14  spaced apart from each other to produce the hermetic insulating “insulating air space”  20  between them. The frame  16  and the sealant body  18  co-act to provide a structure which maintains the lites  14  properly assembled with the space  20  sealed from atmospheric moisture over long time periods during which the unit  10  is subjected to frequent significant thermal stresses. The desiccant body  22  removes water vapor from air, or other volatiles, entrapped in the space  20  during construction of the unit  10 . 
     The sealant body  18  both structurally adheres the lites  14  to the spacer assembly  12  and hermetically closes the space  20  against infiltration of airborne water vapor from the atmosphere surrounding the unit  10 . The illustrated body  18  is formed from a “hot melt” material which is attached to the frame sides and outer periphery to form a U-shaped cross section. 
     The structural elements of the frame  16  are produced by the method and apparatus of the present invention. The frame  16  extends about the unit periphery to provide a structurally strong, stable spacer for maintaining the lites aligned and spaced while minimizing heat conduction between the lites via the frame. The preferred frame  16  comprises a plurality of spacer frame segments, or members,  30   a - d  connected to form a planar, polygonal frame shape, element juncture forming frame corner structures  32   a - d , and connecting structure  34  for joining opposite frame element ends to complete the closed frame shape. 
     Each frame member  30  is elongated and has a channel shaped cross section defining a peripheral wall  40  and first and second lateral walls  42 ,  44 . See  FIG. 2 . The peripheral wall  40  extends continuously about the unit  10  except where the connecting structure  34  joins the frame member ends. The lateral walls  42 ,  44  are integral with respective opposite peripheral wall edges. The lateral walls extend inwardly from the peripheral wall  40  in a direction parallel to the planes of the lites and the frame. The illustrated frame  16  has stiffening flanges  46  formed along the inwardly projecting lateral wall edges. The lateral walls  42 ,  44  add rigidity the frame member  30  so it resists flexure and bending in a direction transverse to its longitudinal extent. The flanges  46  stiffen the walls  42 ,  44  so they resist bending and flexure transverse to their longitudinal extents. 
     The frame is initially formed as a continuous straight channel constructed from a thin ribbon of stainless steel material (e.g.,  304  stainless steel having a thickness of 0.006-0.010 inches). Other materials, such as galvanized, tin plated steel, or aluminum, may also be used to construct the channel. The corner structures  32  are made to facilitate bending the frame channel to the final, polygonal frame configuration in the unit  10  while assuring an effective vapor seal at the frame corners as seen in  FIGS. 3-5 . The sealant body  18  is applied and adhered to the channel before the corners are bent. The corner structures  32  initially comprise notches  50  and weakened zones  52  formed in the walls  42 ,  44  at frame corner locations. See  FIGS. 3-6 . The notches  50  extend into the walls  42 ,  44  from the respective lateral wall edges. The lateral walls  42 ,  44  extend continuously along the frame  16  from one end to the other. The walls  42 ,  44  are weakened at the corner locations because the notches reduce the amount of lateral wall material and eliminate the stiffening flanges  46  and because the walls are stamped to weaken them at the corners. 
     The connecting structure  34  secures the opposite frame ends  62 ,  64  together when the frame has been bent to its final configuration. The illustrated connecting structure comprises a connecting tongue structure  66  continuous with and projecting from the frame structure end  62  and a tongue receiving structure  70  at the other frame end  64 . The preferred tongue and tongue receiving structures  66 ,  70  are constructed and sized relative to each other to form a telescopic joint  72 . See  FIG. 6 . When assembled, the telescopic joint  72  maintains the frame in its final polygonal configuration prior to assembly of the unit  10 . 
     In the illustrated embodiment the connector structure  34  further comprises a fastener arrangement  85  for both connecting the opposite frame ends together and providing a temporary vent for the space  20  while the unit  10  is being fabricated. The illustrated fastener arrangement (see  FIGS. 3 and 6 ) is formed by connector holes  84 ,  82  located, respectively, in the tongue  66  and the frame end  64 , and a rivet  86  extending through the connector holes  82 ,  84  for clinching the tongue  66  and frame end  64  together. The connector holes are aligned when the frame ends are properly telescoped together and provide a gas passage before the rivet is installed. 
     In some circumstances it may be desirable to provide two gas passages in the unit  10  so the inert gas flooding the space  20  can flow into the space  20  through one passage displacing residual air from the space through the second passage. The drawings show such a unit. See  FIGS. 3 and 6 . The second passage  87  is formed by a punched hole in the frame wall  40  spaced along the common frame member from the connector hole  84 . The sealant body  18  and the desiccant body  22  each defines an opening surrounding the hole  84  so that air venting from the space  20  is not impeded. The second passage  87  is closed by a blind rivet  90  identical to the rivet  86 . The rivets  86 ,  90  are installed at the same time and each is covered with sealant material so that the seal provided by each rivet is augmented by the sealant material. 
     The Elongated Window Component Production Line 
     As indicated previously the spacer assemblies  12  and muntin bars  130  are elongated window components  8  that may be fabricated by using the method and apparatus of the present invention. Elongated window components are formed at high rates of production. The operation by which elongated window components are fashioned is schematically illustrated by  FIGS. 7 and 8  as a production line  100  through which a thin, relatively narrow ribbon of sheet metal stock is fed endwise from a coil into one end of the assembly line and substantially completed elongated window components  8  emerge from the other end of the line  100 . 
     The line  100  comprises a stock supply station  102 , a first forming station  104 , a transfer mechanism  105 , a second forming station  110 , a conveyor  113 , a scrap removal apparatus  111 , third and fourth forming stations  114 ,  116 , respectively, where partially formed spacer members are separated from the leading end of the stock and frame corner locations are deformed preparatory to being folded into, their final configurations, a desiccant application station  119  where desiccant is applied to an interior region of the spacer frame member, and an extrusion station  120  where sealant is applied to the yet to be folded frame member. A scheduler/motion controller unit  122  ( FIG. 8 ) interacts with the stations and loop feed sensors to govern the spacer stock size, spacer assembly size, the stock feeding speeds in the line, and other parameters involved in production. A preferred controller unit  122  is commercially available from Delta Tau, 21314 Lassen St, Chatsworth, Calif. 91311 as part number UMAC. 
     The Supply Station  102   
     The stock supply station  102  is illustrated by  FIGS. 9-17 . The station  102  comprises a plurality of rotatable sheet stock coils  124 , an indexing mechanism  126 , and an uncoiling mechanism  128  ( FIG. 10 ). The indexing mechanism  126  is coupled to the sheet stock coils  124  for indexing a selected one of the sheet stock coils to an uncoiling position P U . When a sheet stock coil  124  is located at the uncoiling position P U , a sheet stock end  130  is positioned to be drawn into the first forming station  104  as will be described in detail below. The uncoiling mechanism  128  selectively uncoils sheet stock  125  from a sheet stock coil  124  indexed to the uncoiling position P U  to thereby provide sheet stock to the downstream processing stations. 
     In the illustrated embodiment, the indexing mechanism  126  includes a carriage  132  and a drive mechanism  133  ( FIG. 10 ). The carriage  132  supports the sheet stock coils, such that the sheet stock coils are individually rotatable about a common axis A. The illustrated carriage  132  includes a frame  134  supported by a pair of front wheels  136  and a pair of rear wheels  138 . The wheels  136 ,  138  are secured to the frame  134  such that the carriage is moveable in the direction of axis A. The illustrated front wheels  136  each include an annular groove  140 . The illustrated annular groove are substantially “v” shaped, but it should be readily apparent that any groove configuration could be employed. An elongated gear rack  156  is mounted to the frame  134 . In the illustrated embodiment, the gear rack  156  extends across the length of the carriage  132 . 
     Referring to  FIG. 12 , the frame  134  includes a plurality of spaced members  142  that extend from a front  144  of the frame  134  to a rear  146  of the frame. A coil support post  148  extends upward from each member  142 . Individual coil support shafts  150  are removably supported between each pair of adjacent coil support posts  148 . The individually removable shafts  150  allow individual sheet stock coils  124  to be installed on the carriage and removed from the carriage. A pair of loop defining supports  152  extend from the outer coil support posts. A coil end support member  154  extends between the pair of loop defining supports  152 . 
     In the illustrated embodiment, the carriage  132  rides on a track  162 . The track  162  includes a front rail  164  and a rear rail  166 . An elongated angular member  168  is secured to an upper surface  170  of the front rail  164 . The angular member  168  is sized and shaped to co-act with the grooves  140  in the front wheels  136 . The angular member  168  and the front wheels  136  form a guide that limits movement of the carriage to be in the direction of axis A. It should be readily apparent that many other types of guides could be employed without departing from the spirit and scope of the claimed invention. 
     The illustrated track  162  is supported by legs  172 . A stop  174  is included at each end of the track. The stops  174  prevent the carriage  132  from moving off the end of the track  162 . A sensor  176  is included near each end of the track. The sensors  176  are coupled to the controller  122 . The sensors are used to detect when the carriage is approaching a stop  174  and to detect the position of the carriage on the frame to allow the controller to establish a “home” position when the stock supply station  102  is initialized. 
     Referring to  FIG. 14 , the illustrated drive mechanism  133  is controlled by the controller  122  and coupled to the carriage  132 . The controller  122  controls the drive mechanism  133  to move the carriage  132  to position a selected one of the coils  124  at the uncoiling position P U . The illustrated drive mechanism  133  includes the gear rack  156  attached to the carriage, a motor  178 , a drive gear  180 , and an engagement actuator  182 . The drive gear  180  is coupled to the motor  178  and is positioned by the engagement actuator  182 . The controller  122  controls the engagement actuator to selectively move the drive gear  180  between an engaged position (shown in phantom in  FIG. 14 ) and a disengaged position (shown as solid in  FIG. 14 ). In the engaged position, teeth of the drive gear  180  mesh with the teeth of the gear rack  156 . The motor  178  is controlled by the controller  122  to position the carriage. The motor  178  is a servo drive motor that can be precisely controlled by the controller  122  to position an appropriate one of the plurality of sheet stock coils  124  at the uncoiling position P U . Controlled energization of the motor  178  positions the carriage  132  is position for threading a corresponding sheet into the forming station  104  In the disengaged position, an operator is able to manually move the carriage  132  on the track  162 . In an alternate embodiment, the engagement actuator is omitted and the drive gear  180  is positioned in the in the engaged position. In this embodiment, an operator is not able to manually move the carriage  132  on the track without manually removing the drive gear  180  from engagement with the gear rack  156 . 
     Referring to  FIGS. 11 and 12 , each sheet stock coil  124  is mounted to a rotatable disk  184 . In the illustrated embodiment, each sheet stock coil  124  is secured between the rotatable disk  184  and a plate  186 . The coil support shaft  150  extends through and supports the sheet stock coil  124 , the rotatable disk  184 , and the plate  186 , such that the sheet stock coil  124 , the rotatable disk  184 , and the plate  186  are rotatable about axis A. Rotation of the disk  184  as indicated by arrow  188   FIG. 13B  causes sheet stock  125  to be unwound off of the coil  124 . 
     Referring to  FIGS. 13A and 13B , a brake assembly  190  is connected to the carriage  132  at each rotatable disk location. The brake assembly  190  prevents the sheet stock from inadvertently unwinding from the coil  124 . The brake assembly includes a pivotable arm  192 , a brake pad  194  mounted at one end of the pivotable arm, an engagement wheel  196  mounted at another end of the pivotable arm, and a biasing member  198 , such as a spring, that biases the pivotable arm to a braking position ( FIG. 13A ). The pivotable arm  192  is pivotably mounted to the carriage  132 . In the braking position, the brake pad  194  engages the rotatable disk and prevents the coil  124  from inadvertently unwinding. In a disengaged position ( FIG. 13B ), the brake pad is not in engagement with the disk  184  and the coil  124  may be unwound. 
     A wide variety of sheet stock widths can be loaded on the stock supply station. For example, a window manufacturer that makes one size of elongated window component could load all of the disks with one size of sheet stock. This may allow the line to run for an entire shift or more, without the need for an operator to load a new coil onto the stock supply station. A window manufacturer that makes a variety of different widths of elongated window components would load the stock supply station with sheet stock coils have a variety of different widths and have multiple coils for commonly used sizes. 
     Referring to  FIGS. 12 ,  13 A and  13 B, the uncoiling mechanism  128  is positioned to individually drive each of the rotatable sheet stock coils  124  when positioned at the uncoiling position P U  to individually uncoil the sheet stock  123  from each of the coils. In the illustrated embodiment, the position of the uncoiling mechanism  128  is fixed with respect to the track  162 . The uncoiling mechanism  128  is controlled by the controller  122  to selectively engage and drive a radially outer surface  200  of the rotatable disk indexed to the uncoiling position P U  to provide sheet stock to the processing station. In the illustrated embodiment, the uncoiling mechanism  128  includes a motor  202 , a drive wheel  204 , an engagement actuator  206 , and a brake plate  208 . The motor  202 , brake plate  208 , and the drive wheel  204  are mounted to a frame  210 . The motor  202  is controlled by the controller  122  and is coupled to the drive wheel  204 . The frame  210  is pivotably connected to the rear of the track  162 . The engagement actuator  206  is controlled by the controller  122  and is coupled to the frame  210  and the track  162 . The actuator  206  selectively pivots the frame  210  between a disengaged position ( FIG. 13A ) and an engaged position ( FIG. 13B ) as dictated by the controller  122 . In the disengaged position, the sheet stock coil  124  at the uncoiling position P U  is prevented from uncoiling by the brake assembly  190 . In the engaged position, the brake plate  208  is in engagement with the wheel  196  and the drive wheel  204  is in engagement with the disk  184 . The engagement of the brake plate  208  with the wheel  196  disengages the brake pad  194  from the disk  184 . Rotation of the drive wheel  204  rotates the disk  184  to uncoil the sheet stock  125 . 
     In the illustrated embodiment, a plurality of clamping mechanisms  212  position the end portion  130  of each of the sheet stock coils  124  such that the end portion of a coil indexed to the uncoiling position U P  is located at an entrance of the first forming station  104 . In the illustrated embodiment, the clamping mechanisms  212  are connected to the coil end support member  154 . In the exemplary embodiment, the motor  202  is controlled to define a loop  213  (See  FIG. 10 ) or droop between each sheet stock coil  124  and its associated clamping mechanism  212 . The illustrated clamping mechanisms  212  each include a support  215 , a pair of guide rollers  216 ,  217 , a clamping roller  218 , and a biasing member  220 , such as a spring. The guide rollers  216 ,  217  limit lateral movement of the sheet stock and thereby guide the sheet stock  125  into the first forming station  104 . The guide rollers  216 ,  217  are rotatably mounted to the support  215 , such that an axis of rotation of each guide roller  216 ,  217  is perpendicular to an upper surface  222  of the support. In the illustrated embodiment, the position of the guide roller  216  is fixed and the position of the guide roller  217  is adjustable to accommodate different sizes of sheet stock  125 . The adjustable guide roller  217  includes a release handle  223  that allows the roller to be selectively moved toward or away from the fixed guide roller  216 . The clamping roller  218  is positioned such that its axis of rotation is parallel to the upper surface  222  of the support  215 . The biasing member  220  is coupled to the clamping roller  218  and the support  215  by a bracket  224  such that the clamping roller  218  is biased toward the upper surface  222 . The clamping roller presses the sheet stock  125  against the upper surface  222  to thereby guide the sheet stock  125  into the first forming station  104 . 
     The width and depth of the frames  16  being produced may be changed from time to time as desired by passing wider or narrower sheet stock through the production line. In addition, sheet stock coils eventually run out of stock and need to be replaced. When it is necessary to change coils, the controller  122  simply indexes the next selected sheet stock coil  124  to the uncoiling position PU, to position the sheet stock end  130  at the entrance to the first forming station  104 . 
     In the illustrated embodiment, a loop feed sensor  230  is included at the supply station. The loop feed sensor  230  ( FIGS. 10 and 12 ) co-acts with the controller unit  122  to control the motor  202  for preventing paying out excessive stock while assuring a sufficiently high feeding rate through the production line. The loop feed sensor  230  is schematically illustrated as positioned above the sheet stock  125  at the uncoiling position P U  that extends from the sheet stock coil  124  to its associated clamping mechanism  212 . Stock fed to the clamping mechanism  212  from the supply station  102  droops in a caternary loop  232  ( FIG. 10 ). The depth of the loop  232  is maintained between predetermined levels by the controller  122 . The illustrated loop feed sensor  230  is an ultrasonic loop detector which directs abeam of ultrasound against the lowermost segment of the stock loop. The loop feed sensor  230  detects the loop location from reflected ultrasonic waves and signals the controller unit  122 . A signal is output from the loop feed sensor  230  to the controller unit  122 . The controller  122  controls the motor  202  to control the feed rate of stock to the production line. 
     A sensor  175  senses the amount of sheet material left on a given stock coil  124 . The preferred sensor includes a IR source positioned above the uncoil position P U . When the coil  124  is full or only partially dispensed the radiation from the source  175  bounces off the sheet material and the sensor does not receive a return signal. When the strip nears an end of its payout, the radiation traverses a path to a reflector  175   a  and bounces back to a photodetector included in the sensor  175 . This signals the controller  122  that the coil at the uncoil position P U  has been dispensed and another coil should be moved into position for unwinding. 
       FIG. 12A  depicts an alternate supply station  102 ′ that includes a plurality of rotatable sheet stock coils  124  that are mounted to a carriage  132 ′. The carriage is similar to a turntable that is drive by an indexing system having a servo motor (not shown) that precisely rotates one of the coils  124  to a uncoil position P U . The supply station  102 ′ includes a single stationary uncoiling mechanism  128  similar to the mechanism described above. The carriage  132 ′ also supports a plurality of brake mechanisms (not shown) and clamping mechanisms  212 . Under control of the controller  122 , the servo motor rotates a particular one of the coils  124  to the uncoil position Pu (or orientation) such that an associated clamping mechanism is juxtaposed in relation to the forming station  104  for feeding stock material  125  from the coil into the forming station for subsequent processing described below. 
     The Forming Station  104   
     The forming station  104  ( FIGS. 18-22 ) withdraws the stock from the clamping mechanism  212  positioned at the uncoiling position P U  and performs a series of stamping operations on the stock passing through it. The station  104  comprises a supporting framework  238  fixed to the factory floor adjacent the loop sensor, a stock feed mechanism  240  that feeds the sheet stock end  130  ( FIG. 10 ) into the forming station, a stock driving system  242  which moves the stock through the station, and stamping units  244 ,  246 ,  248 ,  250 ,  252 ,  254  where individual stamping operations are carried out on the stock. 
     Referring to  FIG. 20 , the illustrated stock feed mechanism  240  comprises a pair of drive rollers  256 ,  258  secured to the framework  238  along a stock path of travel P at a processing station entrance  260 . The pair of drive rollers  256 ,  258  are selectively moveable between a disengaged position (shown in phantom in  FIG. 20 ) where the drive rollers are spaced apart and an engaged position (shown in solid in  FIG. 20 ) where the drive rollers engage a coil end portion positioned at the entrance of the processing station by a clamping mechanism  212  that is located at the uncoiling position P U . The drive rollers  256 ,  258  selectively feed the sheet stock positioned at the entrance of the processing station  260  into the processing station  102 . In the illustrated embodiment, drive roller  256  is selectively driven by a motor  262  that is controlled by the controller  122 . The drive roller  258  is pivotally connected to the framework  238 . In the illustrated embodiment, the roller  258  is an idler roller that presses the sheet stock  125  against the roller  256  when the drive rollers are in the engaged position. An actuator  264  is connected to the framework  238  and the drive roller  258 . The actuator  264  is selectively controlled by the controller  122  to engage sheet stock  125  positioned at the entrance of the stamping station  104 . The motor  262  is controlled to feed the sheet stock  125  through the station  104  to the stock driving station  242 . In the illustrated embodiment, a sensor  266  is positioned along the path of travel P, near the stock feed mechanism. The sensor  266  is used to verify that stock  125  is being fed by the stock feed mechanism  240  and to determine when the stock feed mechanism can be disengaged, because the stock  125  has reached the stock driving system. The controller  122  is in communication with the supply station  102  and the stock feed mechanism. The controller moves the pair of drive rollers to the disengaged, spaced apart position and indexes the selected sheet stock coil to the uncoiling position. At the uncoiling position, the corresponding clamping mechanism  212  positions the sheet stock end portion  130  between the pair of drive rollers  256 ,  258 . The controller  122  moves the pair of drive rollers to the engagement position to engage the coil end portion, and rotates the drive rollers to feed the sheet stock into the processing station and to the stock driving mechanism  242 . 
     In one embodiment, the stock feed mechanism  240  is also used to withdraw stock from the stamping station  104  when sizes are changed as will be described in further detail below. The sensor  266  is used by the controller to determine the when the feeding mechanism  240  stops withdrawing stock from the stamping station. 
     Referring to  FIGS. 18 and 19 , the stock driving system  242  engages the stock provided by the stock feeding mechanism  240 . The stock feeding mechanism  240  then disengages. The stock driving system  242  comprises a stock driving roll set  268  secured to the framework  238  along the stock path of travel P at the exit end of the station  104 , a motor  270  ( FIG. 19 ) is operated by the controller unit  122  for precisely driving the roll set  268 , and a positive drive transmission  272  couples the motor  270  and the roll set  268 . 
     The preferred roll set comprises a pair of drive rolls rigidly supported by bearings secured to the framework  268 . The rolls define a nip for securely gripping the stock and pulling it through the station  104  past the stamping units  244 ,  246 ,  248 ,  250 ,  252 ,  254 . In the illustrated embodiment, the rolls grip the stock so tightly that there is no stock slippage relative to either roll as the stock advances. 
     The illustrated motor  270  is an electric servomotor of the type constructed and arranged to start and stop with precision. Accordingly, stock passes through the station  104  at precisely controlled speeds and stops precisely at predetermined locations, all depending on signals from the controller unit  122  to the motor  270 . While a servo motor is disclosed in the production line  100 , it may be possible to use other kinds of motors or different stock feeding mechanisms. 
     The drive transmission  272  is illustrated as a timing belt reeved around sheaves  274 ,  276  respectively secured to the motor shaft and a shaft of the lower roll. The upper roll being coupled to the lower roll by gears  278  ( FIG. 18 ). The timing belt has tooth-like lugs which positively engage each sheave so that the motor and roll shafts are all driven together without any slippage. Consequently, the motor shaft movement is faithfully transmitted to the roll set  268  by the timing belt so stock motion is controlled as desired in the station  104 . As an alternative, the roll set  268  may be driven by gears connected to the motor shaft. 
     Referring to  FIG. 21 , each stamping unit  244 ,  246 ,  248 ,  250 ,  252 ,  254  comprises a die assembly  280  and a die actuator assembly, or ram assembly,  284 . Each die assembly comprises a die set having a lower die, or anvil,  286  beneath the stock travel path and an upper die, or hammer,  288  above the travel path. The stock passes between the dies as it moves through the station  104 . Each hammer  288  is coupled to its respective ram assembly  284 . Each ram assembly forces its associated dies together with the stock between them to perform a particular stamping operation on the stock. For convenience, the die assemblies and ram assemblies of successive stamping units are identified by common reference numerals having different respective suffix letters. 
     Each ram assembly  284  is securely mounted atop the framework  238  and connected to a source (not shown) of high pressure operating air via suitable conduits (not shown). Each ram assembly  284  is operated from the controller  122  which outputs a control signal to a suitable or conventional ram controlling valve arrangement (not shown) when the stock has been positioned appropriately for stamping. 
     Referring to  FIG. 22 , the stamping unit  252  punches the connector holes  82 ,  84  in the stock at the leading and trailing end locations of each frame member. When included, the passage  87  is also punched in the stock by the unit  252 . In the illustrated embodiment, the die set anvil  286   a  defines a pair of cylindrical openings disposed on the stock centerline a precise distance apart along the stock path of travel P. The hammer  288   a  is formed in part by corresponding cylindrical punches each aligned with a respective anvil opening and dimensioned to just fit within the aligned opening. The ram  284   a  is actuated to drive the punches downwardly through the stock and into their respective receiving openings. 
     The stock is fed into the stamping unit  252  by the driving system  242  and stopped with predetermined stock locations precisely aligned in the stamping station  252 . The punches are actuated by the ram  286   a  so that the connector holes  82 ,  84  are punched on the stock midline, or longitudinal axis. When the punches are withdrawn, the stock feed resumes. 
     Referring to  FIG. 22 , the stamping unit  248  forms the frame corner structures  32   b - d  but not the corner structure  32   a  adjacent the frame tongue  66 . Referring, to  FIGS. 21 and 22 , the unit  248  comprises a die assembly  280   b  operated by a ram assembly  284   b . The die assembly  280   b  punches material from respective stock edges to form the corner notches  50 . The die assembly  280   b  also stamps the stock at the corner locations to define the weakened zones  52  which facilitate folding the spacer frame member at the corner locations. The ram assembly  284   b  preferably comprises a pair of rams connected to the upper die  288   b.    
     Each weakened zone  52  is illustrated as formed by a score line (more than one score line may be included) radiating from a corner bend line location on the stock toward the adjacent stock edge formed by the corner notch  50 . The score line is formed by a sharp edged ridge on the anvil  286   b . In the illustrated embodiment, the frame members produced by the production line  100  have common side wall depths even though the frame width varies. Therefore, the score line on the anvil  286   b  are effective to form the corner structures for all the frame members made by the line  100 . 
     Referring to  FIGS. 21 and 22 , the stamping unit  250  configures the leading and trailing ends  62 ,  64  of each spacer frame member. The unit  250  comprises a die assembly  280   c  operated by a ram assembly  284   c . The die assembly is configured to punch out the profile of the frame member leading end  62  as well as the profile of the adjoining frame member trailing end  64  with a single stroke. The leading frame end  62  is formed by the tongue  66  and the associated corner structure  32   a . A trailing frame end  64  associated with the preceding frame member is immediately adjacent the tongue  66  and remains connected to the tongue  66  when the stock passes from the unit  250 . The ram assembly  284   c  comprises a pair of rams each connected to the hammer  288   c.    
     The corner structure  32   a  is generally similar to the corner structures  32   b - d  except the notches  50  associated with the corner  32   a  differ due to their juncture with the tongue  66 . The die assembly therefore comprises a score line forming a ridge like the die set forming the remaining frame corners  32   b - d.    
     In the illustrated embodiment the stamping unit  246  forms muntin bar clip mounting notches in the stock. The muntin bar mounting structures include small rectangular notches. The unit  246  comprises a ram assembly  284   d  coupled to the notching die assembly  280   d . The anvil  286   d  and hammer  288   d  of the notching die assembly are configured to punch a pair of small square corner notches  289  on each edge of the stock. Accordingly the ram assembly  284   d  comprises a single ram which is sufficient to power this stamping operation. A single stroke of the ram actuates the die set to form the opposed notches simultaneously and in alignment with each other along the opposite stock edges. 
     Referring to  FIG. 22 , the stamping station  104  defines a scrap piece  294  followed by a connected first spacer frame defining length  296  of stock in a given series  297  of spacer frames. In one embodiment, the scrap piece  294  is defined by the stamping station  104  whenever a different coil is indexed to the uncoiling station and fed into the forming station  104 . This prevents the first spacer frame member in a series of spacer frame members made from the indexed coil from being scrapped. Instead, only the scrap piece  294  is scrapped. A first spacer frame member in a series of spacer frame members may otherwise need to be scrapped for a variety of reasons. For example, the leading end  130  of the material initially fed into the station may not be cut to define the leading edge of a spacer frame, the leading edge may be bent, and/or the first spacer frame member may not be properly formed by the second forming station  110 . In the illustrated embodiment, the scrap defining length  296  is substantially shorter (½ as long or shorter for a typical frame) than the length of stock needed to form a typical elongated window component. The resulting scrap sheet stock  125  is thereby reduced. 
     Referring to  FIGS. 21 and 22 , the stamping unit  244  configures the leading edge  298  of the scrap piece  294  and trailing end  64  of the last spacer frame member in a series of spacer frame members formed from the indexed coil  124 . The trailing edge  297  of the scrap unit is formed by the stamping unit  250  when the leading edge of the first spacer in the next series of spacers formed from this particular sheet stock coil is stamped. The unit  244  comprises a die assembly  280   e  operated by a ram assembly  284   e . The die assembly is configured to punch out the profile of the scrap piece leading end  298  as well as the profile of the end  64  of the last frame member in the series of spacer frame members with a single stroke. The ram assembly  284   e  comprises a pair of rams each connected to the hammer  288   e.    
     Referring to  FIG. 22 , at the end of a series of spacer frame members, the stamping unit  244  forms the trailing end of the last spacer frame member in the series and the leading end  298  of the scrap piece. The stock is then indexed to stamping unit  254  where the connection between the end of the last spacer frame member and the leading end  298  of the scrap piece  294  is severed. The unit  1254  comprises a die assembly  280   f  operated by a ram assembly  284   f . The die assembly  280   f  punches the material that spans the respective stock edges to sever the stock. The ram assembly  284   f  preferably comprises a ram connected to the upper die  288   f.    
     Referring to  FIG. 19 , a sensor  300  detects the end of the last spacer frame in a series of spacer frame members. Upon detection of the severed end of the last spacer Fame, the controller  122  causes the stock feed mechanism  240  to move to the engaged position. The controller then actuates the motor  262  to pull the stock  125  out of the stamping station  104  and position the stock end  130  at the entrance to the stamping station. The stock that forms the last spacer frame member in the series is driven out of the machine by the stock driving mechanism  242 . The controller then moves the stock feed mechanism  240  to the disengaged position to release the stock end  130 . The stock end remains secured by its clamping mechanism  212 . The controller may then index the next selected coil to the uncoiling position P U  and thereby place its end  130  between the rollers  256 ,  258 . The controller  122  then controls the stock feed mechanism  240  to start the next series of spacer frame units. 
     In order to accommodate wider or narrower stock passing through the station  102  die assemblies  280   b - e  are split. In the illustrated embodiment, one side of each die assemblies is fixed and the opposite side each split die assembly is adjustably movable toward and away from the corresponding fixed die assembly to form different width spacer frames. Thus, each anvil  286   b - e  is split into two parts and each hammer  288   b - e  is likewise split. To maintain die assembly  280   a  in the center of the path of travel P, die assembly  280   a  is also moveable. 
     Referring to  FIG. 21 , the moveable opposed hammer and anvil parts are linked by vertically extending guide rods  302 . The guide rods  302  are fixed in the hammer parts and slidably extend through bushings in the opposed anvil parts. The guide rods  302  both guide the hammers into engagement with their respective anvils and link the hammers and respective anvils so that all the hammers and anvils are adjusted laterally together. 
     Referring to  FIGS. 19 and 22 , the moveable hammer and anvil parts of each die assembly are movable laterally towards and away from the fixed hammer and anvil parts by an actuating system  304  to desired adjusted positions for working on stock of different widths. The system  304  firmly fixes the die assembly parts at their laterally adjusted locations for further frame production. Referring to  FIG. 21 , the anvil parts of each die assembly  280   a - e  are respectively supported in ways  309  attached to the stamping unit frame  238 . The hammer parts of each die assembly are each supported in ways  311  fixed its respective die actuator, or ram  284   a - e . The ways  309 ,  311  extend transversely of the travel path P and the actuating system  304  shifts the hammer parts and the anvil parts simultaneously along the respective ways between adjusted positions. 
     The illustrated actuating system is controlled by the controller  122  to automatically adjust the station  104  for the stock width provided at the entrance of the station. The width of the stock provided to the station  104  may be detected and the controller automatically adjusts the station  104  to accommodate the detected width. Referring to  FIGS. 19 and 22 , the illustrated actuating system  304  provides positive and accurate moveable die assembly section placement relative to the stock path of travel P. The system  304  comprises a plurality of drivescrews  316 , a drive transmission  318  coupled to the drivescrews, and die assembly driving members  319 ,  320 ,  321 ,  322 ,  323 ,  325  driven by the drivescrews  326  and rigidly linking the drivescrews to the anvil parts. 
     The drivescrews  316  are disposed on parallel axes  324  and mounted in bearing assemblies connected to lateral side frame members  330 . Each drivescrew is threaded into its respective die assembly driving member  319 ,  320 ,  321 ,  322 ,  323 ,  325 . Thus when the drivescrews rotate in one direction the driving members  319 ,  320 ,  321 ,  322 ,  323 ,  325  force their associated die sections to shift laterally away from the fixed die sections. Drivescrew rotation in the other direction shifts the die sections toward the fixed die sections. The threads on the drivescrews are precisely cut so that the extent of lateral die section movement is precisely related to the angular displacement of the drivescrews creating the movement. 
     The hammer sections of the die assemblies are adjustably moved by the anvil sections. The guide rods  302  extending between confronting anvil and hammer die sections are structurally strong and stiff and serve to shift the hammer sections of the die assemblies laterally with the anvil sections. The hammer sections are relatively easily moved along the upper platen ways  311 . 
     In the illustrated embodiment, the drive transmission  318  is driven by a motor  317  that is controlled by controller  122 . The illustrated transmission  318  comprises a timing belt  332  and conforming pulleys  334  on the drivescrews and motor  317  around which the belt is reeved. In the illustrated embodiment, the pulley  334  that drives the die assembly  252  is larger, since the movement of the die assembly  252  is half that of the movement of the other die assemblies. This keeps the gas holes centered on the path of travel of P. The angular position of the screws is measured and provided to the controller  122 . In one embodiment, the station width that corresponds to the measured angular position is displayed on a controller screen  123  where it can be read by the operator. In one embodiment a digital encoder (not illustrated) is associated with one of the jackscrews. The encoder is coupled, via the scheduler/motion controller unit  122 . Precise movement of the jackscrews is accomplished using the motor  317  linked to and controlled by motion control unit  122 . 
     The stock moves through the forming station  104  intermittently, stopping completely at each location where it is stamped. The average rate of stock feed can vary widely from one frame member to the next. For instance, if the station  104  forms a spacer frame member for ultimate use in a large “picture” window having no muntin bars, the rate of stock feed is relatively high because the stock is stopped only to stamp the corner structures, the frame ends and to punch holes. The stock moves continuously (and may move rapidly) through the station between corner structure locations. 
     If the immediately succeeding spacer frame is intended for use in a relatively small window having a number of muntin bars the stock feed must be stopped to stamp all the muntin bar connection locations as well as the remaining stamping operations. The average rate of stock feed in this case is low because of all the stops. 
     Transfer Mechanism  105   
     Referring to  FIG. 23 , the transfer mechanism  105  automatically feeds the elongated sheet stock  125  from the stamping station  104  into a down stream station, such as a roll forming station  110  in the window component production line  100 . The transfer mechanism is positioned between the stamping station  104  and the roll forming station  110 . In the illustrated embodiment, the transfer mechanism  105  provides the stamped sheet stock to a feed mechanism  360  positioned at an entrance to the roll forming station  110 . The controller  122  is in communication with the stamping station  104 , the transfer mechanism  105 , and the feed mechanism  360 . The controller  122  causes the transfer mechanism to engage stock material  125  that extends from the stamping station  104  and transfer the stock material paid out by the stamping station to the feed mechanism. The controller  122  then drives the feed mechanism to feed the elongated sheet stock into the roll forming station  110 . In the illustrated embodiment, the stamping station  104  and the roll forming station  110  are controlled by the controller  122  to create a caternary loop  362  ( FIG. 24 ) between the stamping station and the roll forming station. 
     Referring to  FIGS. 25-27 , one acceptable transfer assembly  105  comprises a pair of gripping members  364 , a conveyor  366 , and a conveyor support frame  368  ( FIGS. 23 and 24 ). The controller selectively causes the conveyor  366  to move the pair of gripping members  364  between the exit of the stamping station  104  to an entrance of the feed mechanism. It should be readily apparent that the transfer could take a variety of other forms without departing from the spirit and scope of the claimed invention. For example,  FIG. 28  illustrates an automatic transfer assembly that comprises a bridge  370  that supports the stock material as the stock material is transferred to the feed mechanism  360  and allows the stock to droop once the stock is engaged by the feed mechanism.  FIG. 29  illustrates a transfer assembly that defines a path of travel  361  between the stamping station and the roll forming station that includes a droop. 
     In the illustrated embodiment, the gripping members  364   a ,  364   b  are positioned next to the conveyor  366 . A moveable gripping member  364   b  is coupled to a pneumatic actuator  372 . A pressurized air source, coupled to the pneumatic actuator  372 , is controlled by the controller  122  to selectively move the gripping member  364   b  between an engaged position (shown in solid in  FIGS. 25 and 26 ) and a disengaged position (shown in phantom in  FIGS. 25 and 26 ). The illustrated conveyor  366  includes a carriage  374 , a rail  376 , and an actuator  378  that moves the carriage along the rail under the control of the controller  122 . The pneumatic actuator  372  is mounted to a carriage  374 . The controller  122  controls the actuator  378  to move the gripping members between the stamping station  104  and the roll forming station  110 . 
     Feed Mechanism  360   
     Referring to  FIGS. 30-32 , the illustrated feed mechanism  360  comprises a pair of drive rollers  379 ,  380  positioned along the stock path of travel P at a processing station entrance  382 . The pair of drive rollers  379 ,  380  are selectively moveable between a disengaged position where the drive rollers are spaced apart and an engaged position where the drive rollers engage a coil end portion positioned at the entrance of the roll forming station  110  by the transfer mechanism  105 . The drive rollers  379 ,  380  selectively feed the sheet stock positioned at the entrance  382  into the processing station  110 . In the illustrated embodiment, drive roller  379  is selectively driven by a motor  384  that is controlled by the controller  122 . The drive roller  379  and the motor  384  are pivotally connected to the station  110 . In the illustrated embodiment, the roller  380  is an idler roller that presses the sheet stock  125  against the roller  379  when the drive rollers are in the engaged position. An actuator  386  is connected to the station  110  and the drive roller  380 . The actuator  386  is selectively controlled by the controller  122  to engage sheet stock  125  positioned at the entrance of the roll forming station  110  by the transfer mechanism. The motor  384  is controlled to feed the sheet stock  125  into the station  110 . In the illustrated embodiment, a sensor is positioned along the path of travel P, near the stock feed mechanism. The sensor is used to verify that stock  125  is being fed by the stock feed mechanism  360 . 
     The controller  122  is in communication with the stamping station  104 , the gripping member actuator  372 , the drive roller actuator  386 , and the conveyor  366 . When stock  125  that defines a series of units is paid out by the stamping station  104 , the controller  122  pivots the gripping member  364   b  to the spaced apart, disengaged position and positions the gripping members  364   a ,  364   b  (check drawings) at the exit of the stamping station  104 . This positions the stock material end portion  130  between the gripping members  364 . The controller then moves the gripping member  364   b  to the engaged or gripping position to grip the end portion. The controller  122  moves the pair of drive rollers  379 ,  380  to the disengaged position and moves the gripping members  364  and the end portion to the roll forming station entrance  382  where the end portion  130  is disposed between the drive rollers. In one embodiment, the movement of the gripping members from the stamping station  104  to the roll forming station  110  is incremental, with stops that correspond to stops required to stamp the material in the stamping station. The controller  122  moves the pair of drive rollers  379 ,  380  to the engaged position to engage the end portion  130 . The controller  122  rotates the drive rollers  379 ,  380  to feed the elongated sheet stock into the roll forming station. When the end of the stock that forms the series of spacer frame members is paid out of the stamping station  104 , it falls from the exit of the stamping station and is pulled into the roll forming station. In an alternate embodiment, the transfer mechanism captures the end and transfers it to the roll forming station. 
     The Forming Station  110   
     Referring to  FIGS. 31-33 , the forming station  110  is preferably a rolling mill comprising a support frame structure  442 , roll assemblies  444 - 452  carried by the frame structure, a roll assembly drive motor  454 , a drive transmission  456  ( FIG. 32 ) coupling the drive motor  454  to the roll assemblies, and an actuating system  458  ( FIG. 32 ) for enabling the station  110  to roll form stock having different widths. 
     The support frame structure  442  comprises a base  460  fixed to the floor and a roll supporting frame assembly  462  adjustably mounted atop the base  460 . The base  460  is positioned in line with the stock path of travel P immediately adjacent the transfer mechanism  105 , such that a fixed stock side location of the stamping station is aligned with a fixed stock side location of the roll forming station. The roll supporting frame assembly  462  extends along opposite sides of the stock path of travel P. 
     Referring to  FIG. 33 , the roll supporting frame assembly  462  comprises a fixed roll support units  480  and a moveable roll support unit  482  respectively disposed on opposite sides of the path of travel P. The units  480 ,  482  are essentially mirror images, with the exception that unit  482  is moveable and unit  480  is fixed so only the unit  482  is described in detail with corresponding parts of the units being indicated by like reference characters. Components that allow unit  482  to move are not included in unit  480 . Referring to  FIG. 33 , the top plate  482  comprises a lower support beam  484  extending the full length of the mill, a series of spaced apart vertical upwardly extending stanchions  486  fixed to the beam  484 , one pair of vertically aligned mill rolls received between each successive pair of the stanchions  486 , and an upper support bar  488  fixed to the upper ends of the stanchions. 
     Each mill roll pair extends between a respective pair of stanchions  486  so that the stanchions provide support against relative mill roll movement in the direction of extent of the path of travel P as well as securing the rolls together for assuring adequate engagement pressure between rolls and the stock passing through the roll nips. The support beam  484  carries three spaced apart linear bearing assemblies  489  on its lower side. Each linear bearing is aligned with and engages a respective trackway  474  so that the beam  484  may move laterally toward and away from the stock path of travel P on the trackways  474 . In the illustrated embodiment, the opposite unit  480  is fixed. 
     Each roll assembly  444 - 452  is formed by two roll pairs aligned with each other on the path of stock travel to define a single “pass” of the rolling mill. That is to say, the rolls of each pair have parallel axes disposed in a common vertical plane and with the upper rolls of each pair and the lower rolls of each pair being coaxial. The rolls of each pair project laterally towards the path of stock travel from their respective support units  480 ,  482 . The projecting roll pair ends are adjacent each other with each pair of rolls constructed to perform the same operation on opposite edges of the ribbon stock. The nip of each roll pair is spaced laterally away from the center line of the travel path. The roll pairs of each assembly are thus laterally separated along the path of travel. 
     Each roll comprises a bearing housing  490 , a roll shaft  492  extending through a bearing in the housing  490 , a stock forming roll  494  on the inwardly projecting end of the shaft and a drive pulley  496  on the opposite end of the shaft which projects laterally outwardly from the support unit. The housings  490  are captured between adjacent stanchions as described above. 
     The upper support bar  488  carries a nut and screw force adjuster combination  500  associated with each upper mill roll for adjustably changing the engagement pressure exerted on the stock at the roll nip. The adjuster  500  comprises a screw  502  threaded into the upper roll bearing housing  490  and lock nuts for locking the screw  502  in adjusted positions. The adjusting screw is thus rotated to positively adjust the upper roll position relative to the lower roll. The beam  484  fixedly supports the lower mill roll of each pair. The adjusters  490  enable the vertically adjustable mill rolls to be moved towards or away from the fixed mill rolls to increase or decrease the force with which the roll assemblies engage the stock passing between them. 
     The drive motor  454  is preferably an electric servomotor driven from the controller unit  122 . As such the motor speed can be continuously varied through a wide range of speeds without appreciable torque variations. 
     Referring to  FIG. 32 , the transmission  456  couples the motor  454  to the roll assemblies  444 - 452  so that the roll assemblies are positively driven whenever the servomotor is operated. The transmission  456  comprises a motor output shaft and sprocket arrangement  512 , a drive shaft  514  disposed laterally across the end of the rolling mill, a drive chain  516  coupling the motor shaft to the drive shaft, and drive chains  518  coupling the drive shaft  514  to the respective roll pairs on each opposite side of the rolling mill. The drive chains  518  are reeved around the drive shaft sprocket and around sprockets on each roll shaft  492  on each side of the machine. 
     Whenever the motor  454  is driven, the rolls of each roll assembly are positively driven in unison at precisely the same angular velocity. The roll sprockets of successive roll pairs are identical and there is no slip in the chains so that the angular velocity of each roll in the rolling mill is the same as that of each of the others. The slight difference in roll diameter provides for the differences in roll surface speed referred to above for tensioning the stock without distorting it. 
     The disclosed roll forming station  110  has an automatic chain tensioner for assuring adequate tension in the drive chain  518 . In a prior art roll forming system the drive chain would require periodic chain tension adjustment with resultant down time of the system. The presently disclosed roll forming station includes a tensioning sprocket  520  rotatably supported by a movable mounting block  521 . In accordance with a presently preferred system at the conclusion of each strip, the controller  122  activates a drive cylinder  522  that has a output shaft coupled to the mounting block  521 . This drives the mounting block down thereby driving the sprocket  520  down and tensions the drive chain  518 . 
     A preferred drive cylinder is air actuated and is commercially available as Festo part number KPE-16 or 178467. The air applied to the drive cylinder delivers a uniform tensioning force to the mounting block  521 . Prior to this force being applied by a valving system coupled to the controller, the controller  122  releases a clamp  523  which frees the output shaft for movement. Once the sprocket  520  is properly tensioned, the controller applies air through coupling  525  to a brake  524  which clamps the shaft and maintains tension until a next subsequent chain tensioning is performed by the controller  122 . 
     In the exemplary embodiment, the actuating system  458  is driven by the controller to automatically adapt the roll forming station  110  to the width of sheet stock to be presented to roll forming station  110 . Referring to  FIG. 32 , the actuating system  458  shifts the moveable roll laterally towards and away from the fixed roll of each roll assembly so that the stock passing through the rolling mill can be formed into spacer frame members having different widths. Referring to  FIG. 33 , the actuating system  458  comprises a pair of threaded drivescrews  530 , a motor  531  that is controlled by the controller  122 , and a drive transmission  532  that couples the motor  531  to the drivescrews  530 . The drivescrew is mounted in a bearing fixed to the rails  472 . The support beam  484  on the moveable side is threaded onto the drivescrew thread so that when the drivescrew is rotated in one direction the moveable beam and its rolls are moved laterally toward the fixed rolls while drivescrew rotation in the opposite sense moves the moveable rolls away from the fixed rolls. The moveable beam  484  moves along the trackways  474  with the aid of the linear bearings  489  during its position adjustment. 
     The drive transmission  532  is preferably a timing belt reeved around sheaves on the drivescrews. The actuating system  458  is substantially like the actuating system  200  described above. Further details concerning the construction of the actuating system  458  can therefore be obtained from the foregoing disclosure of the system  200 . Details of another suitable roll forming station that can be used in accordance with the present invention can be found in U.S. Pat. No. 5,361,476 to Leopold, which is incorporated herein by reference in its entirety. 
     Referring to  FIGS. 23 and 24 , an upper loop feed sensor  550  and a lower loop feed sensor  552  function to ensure that the stock advancing rates of the station  104  and the forming station  110  does not place undue stress on the stock  125 . The loop feed sensors  550 ,  552  co-act with the controller  122  to control the stock feed through the stations  104  and  110 . In one embodiment, the speed of the roll forming station  110  is increased if the lower loop feed sensor  552  senses that the caternary stock loop is below the lower stock feed sensor. This will reduce the caternary loop  362  (i.e. reduce the amount of stock between the stations). The controller  122  will stop the roll forming station  110  or reduce the speed of the roll forming station if the upper sensor  550  senses that the caternary stock loop  362  is above the upper sensor. This will increase the caternary loop  362  (i.e. increase the amount of stock between the stations). 
     The Forming Stations  114 , 116   
     Referring to  FIGS. 34-37 , the forming stations  114 ,  116  are disposed together on a common supporting unit  550 . The controller  122  controls the stations  114 ,  116  to subject the frame members to a swedging operation at the station  114  and a cut off operation at the station  116 . The swedging operation produces the narrowed frame member tongue section which is just narrow enough to be telescoped into the opposite frame end when the spacer frame is being fabricated. The cut off operation is performed between the tip of each frame tongue section and the adjacent trailing end of the preceding frame member. The tongue and trailing end are joined by a short rectangular tang of the stock material which is sheared by the cut off operation. 
     The swedging station  114  comprises a supporting framework  560 , first and second swedging units  562 ,  564  disposed along opposite sides of the stock path of travel P and an actuator system  566  for the swedging units. The framework  560  is mounted on top of the supporting unit  550  and is comprised of structural members welded together to form an actuator supporting superstructure above the path of stock travel P and a work station bed  570 . The bed  570  extends beneath and supports the structural members of the superstructure. 
     The swedging units  562 ,  564  are essentially mirror images of each other, with the exception that unit  562  is laterally adjustable and unit  564  is fixed, and therefore only the moveable unit  562  is described in detail. Some parts of the laterally adjustable unit  562  may not be required on the fixed unit  564 . The swedging unit  562  engages and deforms one frame member tongue side wall to reduce the span of the tongue. This enables the frame ends to be telescoped into engagement when the frame is being assembled. The unit  562  comprises a swedging body  572  stationed on the bed  570 , an anvil assembly  574  carried by the body  572  and a swedging tool assembly  576  supported by the body  572  for coaction with the anvil assembly  574 . 
     The swedging body  572  comprises a plate-like base  580  adjacent one lateral side of the frame member path of travel P, a swedge mount member fixed to the base  580  adjacent the path of travel, and an upstanding stop member which projects away from the base toward the actuator system for limiting the travel of the actuator system as the frame tongue is swedged. 
     The moveable base  580  is supported on the bed  570  by way of forming members (see  FIG. 37 ) so the base position is adjustable laterally toward and away from the fixed base  580 . The base  580  defines a frame guide portion  588  extending under the side of a frame member moving along the path of travel P through the swedging station. The guide portion  588  supports the frame member on the travel path during swedging. The base member position adjustment shifts the guide portion  588  to accommodate different width frame members. A corresponding fixed guide portion  588 ′ is aligned with the fixed stock edge locations defined by the stamping unit  104  and the roll forming unit  110 . 
     The swedge mount member is rigidly fixed to the base  580  and projects upwardly. The member supports the anvil assembly for vertical movement to and away from a frame member being swedged and supports the swedging tool assembly  576  for horizontal motion into and away from engagement with the frame member. 
     The anvil assembly  574  is positioned to support and engage the tongue side wall at the conclusion of the swedging operation to define the tongue side wall shape. The anvil assembly  574  comprises an elongated anvil member  590  and a pair of actuator rod assemblies  592  supported by the body  572  for transmitting movement from the actuator system  566  to the anvil member. 
     The anvil member  590  has an elongated blade-like projecting element  596  extending downwardly for engagement with the frame member. The lengths of the anvil member  590  and blade portion  596  correspond to the length of the frame member tongue wall so that the element  596  coextends with the tongue and for supporting the tongue wall throughout its length during swedging. 
     The actuator rod assemblies  592  force the blade portion  596  of the anvil member  590  into engagement with the frame member during swedging and withdraw the anvil member from the frame member when swedging is completed. The rod assemblies  592  are spaced apart with each projecting through a bore in the swedging member  572 . The rod assemblies are identical and therefore only one is illustrated and described. 
     The swedging tool assembly  576  comprises an elongated tool body  610  extending through a horizontal guide opening in the swedge mount member, a hardened swedging nose element  612  fixed to the end of the body  610  adjacent the travel path P and an actuating cam element  614  adjacent the opposite end of the body  610 . 
     The cam element  614  has a wedge-like face which is engaged by a complementary wedge face  615  of the actuator system to force the tool assembly to swedge the frame tongue. The actuating force serves to move the nose element  612  into engagement with the frame side wall. 
     The nose element  612  is constructed to match the length of the anvil blade-like element  596  so that the swedging procedure is completed with the nose element and the blade-like element confronting along their lengths with the frame side wall clenched between them. After swedging, the nose element  612  projects slightly from the swedge mount member to provide a lateral guide for frame members passing along the path P. 
     The actuator system comprises a pair of pneumatic rams  620  attached to the framework  560  above the cut off and swedging stations, an actuator platen  622  fixed to the rams for vertical reciprocating motion when the rams are operated, and actuating cam assemblies  624  supported by the platen for operating the swedging station. 
     The cam assembly  624  operates the swedging unit  562 . The cam assembly  624  includes a camming member  634 . The lower end of the camming member defines a wedge face  615  which coacts with the wedge-like face on the cam element  614 . The downward travel of the camming member  634  is the same regardless of how wide the frame member in the swedging unit might be. 
     One of the sets of swedging and actuator parts are laterally fixed and the other set of swedging and actuator parts are movable laterally towards and away from the fixed set by an actuating system  650  to desired adjusted positions for working on stock of different widths. The system  650  firmly fixes the laterally adjustable parts at their laterally adjusted locations for further frame production. As noted, the laterally moveable parts are supported in ways extending transverse to the direction of extent of the travel path P. The actuating system  650  shifts the laterally moveable parts simultaneously along the respective ways between adjusted positions. In the exemplary embodiment, the actuating system  650  is driven by the controller. In the exemplary embodiment, the width of station  114  is automatically adjusted by the controller based on the width of formed spacer frame stock received from the roll forming station. 
     The preferred and illustrated actuating system  650 , like the system  200  described above, provides extremely accurate information regarding placement relative to the stock path of travel P. The system  650  comprises a single threaded drivescrew  652  and a swedging unit drive member  656  driven by the drivescrew. 
     The drivescrew  652  is mounted in a bearing assembly  658  connected to the framework  60 . The drivescrew  652  is threaded into the swedging unit drive member  656 . When the drivescrew rotates in one direction the driving member  656  forces the moveable swedging units to shift laterally away from the fixed swedging units. Drivescrew rotation in the other direction shifts the assemblies toward the fixed swedging units. The threads on the drivescrew are precisely cut so that the extent of lateral movement is precisely related to the angular displacement of the drivescrew creating the movement. The moveable actuating cam assemblies are moved by the swedging unit assemblies via the guide rods  636  ( FIG. 37 ) when the lateral positions are adjusted. 
     The angular position of the jackscrew is measured and used by the controller to control the width of the station  114 . In the exemplary embodiment, the station width is automatically set by the controller based on the width of the elongated spacer frame  16  formed by the roll forming station to be provided to the station  114 . In one embodiment a digital encoder (not illustrated) is associated with the jackscrew. In the illustrated embodiment, the fixed swedging and actuator parts are fixed such that the fixed reference of the station  114  is aligned with the fixed references of stations  104  and  110 . 
     Referring to  FIG. 38 , the cut-off unit  116  is located axially adjacent the swedging unit in the direction of frame member travel along the path P. The cut-off unit comprises an elongated cut-off blade  680  extending in a plane transverse to the direction of the travel path P and a pair of blade supporting rods  682  fixed to the platen  622  at their upper ends and fixed to the blade  680  at their lower ends. The blade  680  is laterally wider than the widest frame member passing through the unit and extends into vertically oriented slots formed in the swedge mount members  582  on opposite sides of the path P. The swedge mount member slots are sufficiently wide that they accommodate and guide the blade  680  regardless of the adjusted swedge mount member positions relative to the centerline of the path P. 
     The actuator system operates the swedging unit at the same time the cut-off unit is operated. Accordingly, when the tongue at the leading end of a frame member is being swedged the preceding frame member is cut-off from the stock and is free to move from the forming stations  114 ,  116  to the extrusion station  120 . Additional details and embodiments of acceptable swedging and forming stations  114 ,  116  are disclosed in U.S. Pat. No. 5,361,476, which is incorporated herein by reference in its entirety. 
     In one embodiment the forming stations  114 ,  116  perform their operations without requiring that the stock moving along the travel path P be stopped or slowed down. This may be accomplished by reciprocating the bed  570  carrying the stations  114 ,  116  relative to the supporting unit  550  in the direction of the path of travel so that the swedging and cut-off operations are performed on the stock moving along the path. Details of one acceptable reciprocating mechanism are disclosed in U.S. Pat. No. 5,361,476 to Leopold, which is incorporated herein by reference in its entirety. 
     Conveyor  113   
     The conveyor  113  transports the formed and separated elongated spacer frames  16  from stations  114 ,  116  to stations  119 ,  120  where desiccant  22  and adhesive  18  are applied. The illustrated conveyor  113  includes vertical supports  800   a ,  800   b ,  800   c ,  800   d , an elongated support  802  that extends along the path of travel, rollers  804 ,  805 , a belt  806  disposed around the elongated support and rollers, a motor  808 , and a guide  810 . The vertical supports  800  position the elongated support  802  along the path of travel P. The motor  808  drives roller  804  to drive the belt  806 . The motor  808  is controlled by the controller  122 . The belt  806  delivers the elongated spacer frames from stations  114 ,  116  to stations  119 ,  120 . The guide  810  keeps the elongated spacer frames on the path of travel P. The guide  810  is adjustable to accommodate spacer frame members of varying widths. 
     In the illustrated embodiment, the guide  808  includes a fixed guide member  812  and a laterally adjustable guide member  814 . The fixed guide member  808  is aligned with the fixed reference of station  114 . In one embodiment, a pair of conveyor guides of stations  119 ,  120  are symmetrically adjustable with respect to the center of the path of travel P. In the illustrated embodiment, the end  816  of the conveyor  113  is automatically positioned to align the center of the path of travel P defined by the fixed guide member  812  and adjustable guide member  814  with the symmetrically adjustable conveyor guides of stations  119 ,  120 . In the illustrated embodiment, an adjustment mechanism  820  adjusts both the position of the moveable guide member  814  and the position of the end  816  of the conveyor. Use of a single adjustment mechanism assures that the movement of the moveable guide member  814  is coupled to the movement of the end  816 . It should be readily apparent that separate mechanisms could be used to position the moveable guide member  814  and the end  816 . 
     The mechanism  820  includes a motor  822 , a transmission  824 , a guide member drive  826 , and a conveyor end drive  828 . The motor  822  is controlled by the controller. The transmission  824  is coupled to the motor  822 . The transmission  824  includes first and second output shafts  830 ,  832 . The first output shaft  830  is coupled to the guide member drive  826 . The guide member drive  826  includes a coupling  834 , cam mechanisms  836 , and linkages  838 . Each cam mechanism  836  includes a first member  840  that is secured to the adjustable guide member  814  and a second member  842  that is secured to the elongated support  802 . The cam members  840 ,  842  are coupled together such that the cam member  840  moves away from the fixed guide member  812  when force in one direction along the path of travel is applied to the cam mechanism  836  and the cam member  840  moves toward the fixed guide member  812  when force in the opposite direction along the path of travel is applied to the cam mechanism  836 . For example, the cam mechanism may be configured such that movement of 0.250 inches of the cam member  840  in a direction along the path of travel results in movement of 0.250 inches of the cam member  840  away from the fixed guide member  812 . Each cam mechanism  836  is connected to the adjacent cam mechanism. The coupling  834  is fixed to the first cam mechanism  836  that is adjacent to the transmission. The first output shaft  830  includes threads  850  that are threaded into threads in the coupling  834 . Rotation of the shaft by the motor  822  applies force to the cam mechanism in the direction of the path of travel, which causes the cam members  840  and the attached guide member to move toward or away from the fixed guide member. The motor  122  is controlled by the controller to control the spacing between the fixed guide member  812  and the moveable guide member  814 . 
     The vertical support,  800   a  is coupled to the elongated support  802  by the conveyor end drive  828  of the adjustment mechanism  820 . The conveyor end drive  828  adjusts the lateral position of the elongated support  802  with respect to the vertical support to align the centerline of the conveyor  113  with the centerline of the stations  119 ,  120 . The second output shaft  832  is coupled to the conveyor end drive  828 . The conveyor end drive  828  comprises a coupling  860  secured to the elongated support  802 . Threads on the output shaft  832  engage threads in the coupling  860 . Rotation of the shaft by the motor  822  adjusts the lateral position of the elongated support  802  with respect to the vertical support. Referring to  FIG. 42 , the elongated support  802  is connected to vertical supports  800   b ,  800   c  such that the elongated support is laterally moveable with respect to the vertical supports  800   b ,  800   c . The elongated support  802  is fixed to vertical support  800   d . When the conveyor end drive moves the conveyor end, the elongated support  802  moves with respect to the vertical supports  800   b ,  800   c . The movement at the elongated support  802  is minimal and is accounted for by flexing of the elongated support. The vertical support  800   d  acts as a pivot point. The centerline of the conveyor  113  is substantially maintained in alignment with the centerline of the station  114  and the centerline of the stations  119 ,  120  when widths are adjusted. The motor  122  is controlled by the controller to automatically align the conveyor. 
     In the illustrated embodiment, a series of wheels  803  are attached to the conveyor  113  above the belt. The wheels  803  help to maintain the elongated spacer frame members  16  against the conveyor belt. The wheel  803 ′ that is adjacent to the cutoff station  116  is coupled to a force application actuator  805  that is controlled by the controller. The actuator  805  selectively urges the wheel  803 ′ toward the conveyor belt. This causes the wheel  803 ′ to apply pressure to the elongated spacer member that is exiting stations  110 ,  114 ,  116 . In effect, the actuator  805  and wheel  803 ′ clamp the spacer frame against the conveyor belt. This allows the conveyor belt to pull the elongated spacer frame  16  out of the stations  110 ,  114 ,  116 . 
     Scrap Removal Apparatus  111   
     In the illustrated embodiment, a scrap piece  294  is stamped at the stamping station  104 , roll formed at station  110 , and separated from the first elongated spacer at the station  116  each time a new or different stock coil is initially fed into the station  104 . This prevents the first elongated unit in the series of elongated units from being scrapped. In one embodiment, the scrap piece  294  is automatically removed from the conveyor  113  before it reaches the desiccant and adhesive application station  120 . 
     The scrap removal apparatus  111  automatically removes the leading scrap piece  294  from the conveyor  113 . The scrap removal apparatus includes a path of travel altering mechanism  870  and a translating mechanism  872 . The path of travel altering mechanism  870  is positioned along the path of travel P. The path of travel altering mechanism  870  selectively facilitates movement of the scrap piece off the path of travel. The translating mechanism  872  is in communication with the path of travel altering mechanism  870  for moving the scrap piece off of the path of travel. The controller  122  is in communication with the path of travel altering mechanism and the translating mechanism. The controller actuates the path of travel altering mechanism when a scrap elongated window component stock is detected and actuates the translating mechanism  872  to move the scrap elongated window component off the path of travel. 
     In the embodiment illustrated by  FIGS. 43 and 44 , the path of travel altering mechanism  870  includes a guide actuator  874  and a moveable guide portion  876 . In the illustrated embodiment, the moveable guide portion  876  is a segment of the fixed guide member  812 . One guide actuator  874  is coupled to each end of the moveable guide portion  876 . Each guide actuator  874  is also coupled to the elongated conveyor support  802 . The actuators  874  are coupled to a source of fluid pressure that is controlled by the controller  122 . The controller controls the guide actuators  874  to selectively move the moveable guide portion  876  to a raised position (shown in  FIG. 44 ). In the raised position, the guide portion  876  is far enough above the conveyor belt that the scrap segment  294  can be moved off of the conveyor. 
     In the embodiment illustrated by  FIGS. 43 and 44 , the translating mechanism  872  is a blower. The blower is coupled to a source of fluid pressure that is controlled by the controller  122 . The controller controls the blower to selectively move the scrap piece past the moveable guide portion  876  in the raised position and off of the conveyor  113 . In the illustrated embodiment, a sensor  880  is coupled to the controller  122  for detecting the scrap piece  294  on the conveyor. The speed of the conveyor  113  is input to the controller by the conveyor  113 . The controller uses the speed of the conveyor  113  and input from the sensor  880  to determine the time when the scrap piece will pass the moveable guide portion  876 . The controller  122  then moves the guide portion to the raised position accordingly, and actuates the blower when the scrap piece is at the moveable guide portion to discharge the scrap piece. 
     It should be readily apparent to those skilled in the art that the path of travel altering mechanism and the translating mechanism could take a variety of different forms without departing from the spirit and scope of the claims. In the example of  FIGS. 45-47 , the path of travel altering mechanism  870 ′ is in the form of a pair of capturing members  900  coupled to a capturing mechanism actuator  902 . The capturing mechanism actuator is controlled by the controller  122  to selectively moving the pair of capturing members  900  between a spaced apart position ( FIG. 45 ) and a scrap engagement position ( FIG. 46 ). The translating mechanism  872 ′ is coupled to the capturing mechanism for moving the capturing mechanism from a capturing position to a discharge position. Referring to  FIGS. 45 and 46 , the controller  122  is in communication with the capturing member actuator  902 , and the translating mechanism  872 ′. Referring to  FIGS. 46 and 47 , the controller moves the capturing members between a spaced apart position and a capturing position based on a sensed position of a scrap piece  294  to capture the scrap piece and stop its movement along the path of travel. The controller  122  drives the translating mechanism  872 ′ to move the capturing members to the discharge position and drives the capturing actuator  902  to move the capturing members to the spaced apart position to discharge the scrap piece. 
       FIG. 48  illustrates an alternate scrap removal system  111 ′. In the embodiment illustrated by  FIGS. 48-50 , the translating mechanism includes two pushers  910 ,  912 . The pushers  910 ,  912  have generally round contact surfaces  914 ,  916  facing the path of travel of the elongated window component. Two actuators  920 ,  922  coupled to the controller  122  simultaneously move their respective pusher outwardly away from the position shown in  FIG. 48 .  FIG. 49  illustrates one pusher  912  in greater detail. In  FIG. 49  the pusher  912  has its contact surface retracted away from the path of travel of elongated window components as they move along the conveyor  113 . In the position shown in  FIG. 50  the controller  122  has caused the actuator  922  to extend the pusher&#39;s round contact surface  916  through the path of movement followed by the scrap. Simultaneously, the controller  122  causes the other pusher  910  to engage the scrap material. Each of the two actuators  920 ,  922  is an air actuated and coupled to a source of fluid pressure that is controlled by the controller  122 . The controller controls the two pushers to selectively move the scrap piece beneath the moveable guide portion  876 ′ which is raised from the position shown in  FIGS. 48 and 49  to a raised position ( FIG. 50 ) spaced above the path of travel of the scrap piece on the conveyor  113 . In the illustrated embodiment, a sensor  880  is coupled to the controller  122  for detecting the scrap piece  294  on the conveyor. The speed of the conveyor  113  is input to the controller by the conveyor  113 . The controller uses the speed of the conveyor  113  and input from the sensor  880  to determine a time when the scrap piece will pass the moveable guide portion  876 ′. 
     The controller  122  activates two pneumatically controlled cylinders  874 ′ spaced on either side of the pushers  910 ,  912  to move the guide portion  876 ′ to the raised position shown in  FIG. 50  and actuates the two pushers  910 ,  912  when the scrap piece reaches an appropriate position to discharge the scrap piece  294  to the side into a collecting container (not shown). 
     Dessicant Station  119   
     The desiccant application station  119  is controlled by the controller  122  for dispensing of a desiccant  22  into an interior region of an elongated window spacer  16 . The system automatically selects an appropriate desiccant dispensing nozzle and/or automatically determines an appropriate distance D between the desiccant dispensing nozzle and the elongated spacer frame member  16  based on a property of the spacer frame member  16 , such as a width W of the spacer frame member. The station  119  applies desiccant  22  to the interior region of the elongated window spacer  16 . The desiccant  22  applied to the interior region of the elongated window spacer  16  captures any moisture that is trapped within an assembled insulating glass unit. Details of one acceptable desiccant application station  119  are disclosed in U.S. patent application Ser. No. 10/922,745, filed on Aug. 20, 2004 and assigned to the assignee of the present application. U.S. patent application Ser. No. 10/922,745 is incorporated herein by reference in its entirety. 
     Sealant/Adhesive Station  120   
     The extrusion station  120  receives cut off frame members from the conveyor  113  and feeds them endwise to a sealant applying nozzle location where sealant is applied with the frame member in its unfolded “linear” condition. After the sealant is applied the frame member is folded to its finished rectangular configuration, the ends telescoped and the assembly completed as described. 
     The controller  122  controls the sealant station  120  to dispense of an adhesive  18  Referring to  FIG. 2 , the station  120  applies adhesive  18  to glass abutting walls  42 ,  44  and an outer wall  40  of the elongated window spacer  16 . The adhesive  18  on the glass abutting walls facilitates attachment of glass lites  14  of an assembled insulated glass unit. The adhesive on the outer wall  40  strengthens the elongated window spacer  16  and allows for attachment of external structure. The station  120  includes an adhesive metering and dispensing assembly, an adhesive bulk supply, and a conveyor  32 . The pressurized adhesive bulk supply supplies adhesive under pressure to the adhesive metering and dispensing assembly. Details of one acceptable sealant application station  120  are disclosed in U.S. Pat. No. 6,630,029 to Briese et al., which is incorporated herein by reference in its entirety. 
     The frame members  16  proceed to the sealant applying nozzles where the sealant body  18  is applied. Afterward, the frame member is bent to its final rectangular shape and fabrication of the spacer assembly is completed. It should be appreciated that operating control of the production line is closely monitored and exercised by the controller unit  122 . In this regard, it is noted that the controller unit  122  is capable of directing a production run of randomly different length frame members (in which a relatively long frame member can be followed immediately by a relatively short frame member) by controlling the speed of operation of the various forming stations and the ribbon stock accumulations. The controller unit  122  is also capable of directing a production run of randomly different width frame members by controlling the width of the various forming stations and the coil that is indexed to the uncoiling position. The ability to quickly and automatically change spacer frame widths greatly adds to the versatility of the line. The automatic changing of width allows spacers for insulating glass units that need to be remade to be easily inserted into the production sequence of the line  100  without significant time delays in production. 
     In one embodiment, the controller  122  causes the supply station to begin to change the stock size provided at the uncoiling position shortly after the desired amount of stock is paid out, even though one or more downstream processing stations are still processing this stock. Similarly, the controller causes each processing station to change to the next width as soon as the operations being performed on the current stock are completed, even though other downstream stations are still performing operations on the current stock. This reduces the time required to change widths. 
     In one method of changing elongated window component widths, a sheet stock coil with a first width is automatically indexed to the uncoiling position. The sheet stock having the first width is provided to one or more downstream processing station(s). The sheet stock having the first width is processed at the downstream processing station(s). The sheet stock having the first width is severed. A sheet stock coil with a second width is automatically indexed to the uncoiling position while the sheet stock having the first width is being processed by the downstream processing station. Processing of the sheet stock having the first width is completed at the downstream processing station. The downstream processing station is automatically adjusted for processing of the sheet stock having the second width. The sheet stock having the second width is then provided to the downstream processing station where the sheet stock having the second width is processed. 
     In one method of changing elongated window component widths, sheet stock having a first width is provided to a first processing station where it is processed. Sheet stock having the first width is provided from the first processing station to the second processing station where it is processed. The first processing station processing station is automatically adjusted by the controller for processing of the sheet stock having a second width while the sheet stock having the first width is being processed by the second processing station. The second processing station completes processing of the sheet stock having the first width and is then automatically adjusted for processing of the sheet stock having the second width. 
     In the illustrated embodiment, a sheet stock coil with a first width is automatically indexed to the uncoiling position. The sheet stock having the first width is provided to the stamping station  104 . The stamping station  104  performs spacer defining stamping operations on the stock. The transfer mechanism  105  provides the stock from the stamping station to the roll forming station  110 . The roll forming station  110  rollforms the sheet stock to form elongated window component stock. The elongated window component stock is provided from the roll forming station to the swaging and cutoff stations  114 ,  116  where the elongated window component stock is swaged and severed to form individual elongated window components. The elongated window components are provided from the swaging and cutoff stations  114 ,  116  to the dispensing stations  114 ,  116 . The dispensing stations apply desiccant and sealant to the elongated window component. When the stamping station finishes performing its operations on the stock having the first width to define a series of spacers having the first width, the controller causes the stamping station to sever the stock having the first width. The stock driving mechanism  242  drives the leading end of the stock having the first width out of the stamping station  104 . The stock feed mechanism  240  reverses to pull the sheet stock out of the stamping station  104  and positions it in the clamping mechanism  212  for threading into the stamping station at a later time. Once the sheet stock having the first width is removed from the stamping station  104 , the controller drives the stock supply to index a sheet stock having a second width to the uncoiling position, even though the downstream stations  110 ,  114 ,  116 ,  119 ,  120  may still be processing the stock having the first width. The sheet stock having the second width is provided into the stamping station  104 . The stamping station  104  performs spacer defining stamping operations on the sheet stock having the second width, even though the downstream stations  110 ,  114 ,  116 ,  119 ,  120  may still be processing the stock having the first width. When the stock having the first width is driven out of the roll forming station  110 , the controller drives the roll forming station to accept the stock having the second width and/or begin processing the stock having the second width, even though the downstream stations  114 ,  116 ,  119 ,  120  may still be processing the stock having the first width. When the stock having the first width is pulled out of the stamping and severing stations  114 ,  116 , the controller drives the stamping and severing stations  114 ,  116  to accept the stock having the second width and/or begin processing the stock having the second width, even though the downstream stations  119 ,  120  may still be processing the stock having the first width. When the stock having the first width leaves the conveyor  113 , the controller drives the conveyor  113  to accept the stock having the second width, even though the downstream stations  119 ,  120  may still be processing the stock having the first width. When the stock having the first width leaves the dispensing stations  119 ,  120 , the controller drives the dispensing stations to accommodate stock having the second width. 
     Although the present invention has been described with a degree of particularity, it is the intent that the invention include all modifications and alterations falling within the spirit or scope of the appended claims.