GB2490505A

GB2490505A - Roller alignment on conveyors

Info

Publication number: GB2490505A
Application number: GB1107301.2A
Authority: GB
Inventors: Claudio Tognelli; Andy Aldridge; Nigel Fraser; Mike Read; Mike Tubby
Original assignee: BAA IP Holdco Ltd
Current assignee: BAA IP Holdco Ltd
Priority date: 2011-05-03
Filing date: 2011-05-03
Publication date: 2012-11-07
Also published as: GB201107301D0

Abstract

An alignment apparatus and method are disclosed in which a conveyed item is received by a pair of opposed rotatable elements 110, 210, each with a rotation shaft and an outer flexible portion. The conveyed item pushes the rotatable elements to swivel the rotation shafts on swivelling elements, between receiving positions and open positions. The alignment apparatus allows for smooth alignment of items on a conveying mechanism, for example, baggage on a conveyor belt. Also disclosed are three separate methods of making the rotatable elements.

Description

I

ALIGNMENT

Field and Background

The present invention relates generally to alignment and in particular but not exclusively to alignment or positioning of containers or other items conveyed by a conveying mechanism.

In environments in which containers or other items are conveyed by a conveying mechanism, there can be a requirement for those conveyed items to be aligned in a particular orientation or positioned at a particular lateral position across the width of a conveying mechanism transport element. Examples include the package transport industry where parcels and boxes of varying sizes may be conveyed within a sorting or distribution facility in which a particular alignment or position is required to enable efficient processing. Another example is the transportation of baggage, such as in the airline industry, where baggage conveyed within a ground facility such as an airport may need to be aligned or positioned to a particular orientation or lateral position on a conveyor mechanism such as a conveyor belt.

In the airline industry example, it may be appropriate to position baggage to a lateral centre or approximate centre of a conveying mechanism as this can reduce the likelihood of loose straps or buckles on baggage items becoming trapped in side-guards; facilitate offloading from the conveyor mechanism to other devices (such as carts or trays); facilitate scanning of tags attached to baggage by tag readers; and/or facilitate security scanning of baggage conveyed to or through a security scanner facility.

In both of the examples given, it can be seen that the items to be positioned may be of uneven, size, weight, density, shape, consistency and/or materials.

Over the years there have been attempts to achieve the centralisation, e.g. bag position in middle of conveyor, and orientation, e.g. bag longer axis parallel to the direction of travel, of the baggage item being transported on the conveyor belt, some of them being quite complicated and relying on bag positioning detectors and software-driven machines.

Summary

The present invention has been made in view of issues and drawbacks of known systems.

According to a first aspect, there can be provided an alignment apparatus for positioning and/or aligning an item conveyed by a conveying mechanism, the apparatus comprising a rotatable element comprising a rotation shaft rotatable about a rotation axis, the rotatable element further comprising an outer flexible portion; a swivelling element for mounting the rotation shaft and for swivelling the rotation shaft about a swivel point, the swivelling element being arranged to swivel the rotation shaft between a receiving position and an opened position; a support element for mounting the swivelling element, wherein the swivel point is fixed relative to the support element; and a biasing arrangement for exerting a biasing force urging the rotation shaft toward its receiving position. Such an alignment apparatus can be used to provide a "soft-embrace" to item conveyed where the apparatus is provided.

The rotatable element allow for an item to smoothly go through the alignment apparatus whilst the alignment apparatus can still exert a force on the item to align said item. In particular, owing to the biasing arrangement, the alignment apparatus resists a force exerted by a conveyed item pushing the rotatable element away from the receiving position and by resisting said force, exerts an antagonistic force on the item which gently pushes the item toward a desired aligned position. Also, the apparatus may be used to facilitate the alignment of a conveyed item such that the longer axis of said item becomes parallel to the direction of travel. One of the advantages of such an apparatus is that it facilitates alignment of items on a conveyor in a smooth and gentle manner based mostly on a electro-mechanical design and does not rely on complicated software for achieving its main objectives.

The rotatable element may be substantially cylindrical; substantially conical and/or frusto-conical; and/or may comprise at least one concave or convex portion. The shape of the rotatable element may be adapted for example to the type of items it will be used with or to what the apparatus will be used for (for example laying items on their side).

The rotation shaft may be a solid shaft made of strong material, such as steel, for example for providing strength to support the rotatable element and rigidity for avoiding unwanted buckling of the rotation shaft and rotatable element.

The outer flexible portion of the rotatable element may comprise a resilient portion.

Also, the outer flexible portion of the rotatable element may be arranged to exert, relative to the rotation shaft, in response to an inward-directed compression force exerted on a point of compression on the outer flexible portion, an outward-directed force. The magnitude of said outward-directed force increases in an inversely related relation to the distance between said rotation shaft and the point of compression. For example, the magnitude of the outward-directed force may increase in at least an inversely proportional relation to the distance between the rotation shaft and the point of compression. Any item received by the apparatus is therefore received with a "soft embrace" first. If however the item further compresses the outer flexible portion, for example because the item is out of alignment, the opposition from the outer flexible portion then increases. As a result, the more an item is out of alignment, the more the apparatus and the rotatable element will move the item away from its current position toward the desired aligned position. For example, the outer flexible portion may comprise an inner layer and an outer layer, the outer layer being less resilient than the inner layer. Generally, the outer flexible portion of the rotatable element encourages any push on the bag to be gradual, reducing the risk of the bag itself (especially one resting on a convex side) being spun out of control.

The outer flexible portion of the rotatable element comprises bristles. For example, the outer flexible portion may comprise bristles on substantially the entire length of the portion. Also, the outer flexible portion may comprise bristles on a lower region thereof. In one embodiment, the outer flexible portion comprises a core, wherein the core comprises an elastic material and the bristles are bonded to the core. For example, the core may a variable-size core and, optionally, an inflatable core. Such bristles may be outwardly-oriented relative to the rotation shaft on a peripheral portion of the rotatable element; and/or may be arranged in planes normal to the axis of the rotation shaft on a peripheral portion of the rotatable element; and/or may be oriented at an oblique angle relative to a plane normal to the axis of the rotation shaft on an extremity portion of the rotatable element. Also, the outer flexible portion may comprise an inner layer of bristies and an outer layer of bristles, wherein the outer layer of bristles protrudes outwardly relative to the inner layer of bristles. For example, the inner layer of bristles comprises bristles that are stiffer than the bristles of the outer layer of bristles. Bristles may provide the desired soft embrace whilst also being capable of offering a firm resistance to any out of alignment item. Also, providing two or more layers of bristles may be chosen to achieve this soft but firm embrace.

The outer flexible portion may comprise a layer comprising an elastic material, for example foam or rubber. Using an elastic material may help providing a rotatable element which can softly receive an item whilst also providing the desired opposition to out-of alignment bag for facilitating their alignment.

The apparatus further may comprise a receiving position stopper arranged to stop the swivelling element from swivelling further than the receiving position and/or an opened position stopper arranged to stop the swivelling element from swivelling further than the opened position. Such stoppers may help control the position of the swivelling element to avoid said swivelling element swivelling more than recommended, for example, for security and/or efficiency reasons. Also, one of the receiving position and opened position stoppers, at least, may comprise a proximity sensor for detecting when the swivelling element is near the stopper. The proximity sensor may be used for controlling and/or monitoring the operation of the apparatus.

In one embodiment, one of the receiving position and opened position stoppers, at least, is provided on the support element.

The biasing arrangement of the apparatus may be an adjustable biasing arrangement for adjusting the biasing force exerted by said biasing arrangement.

Such an adjustable biasing arrangement may be used for adjusting the tension of the swivelling element when pushed away from its home position by an item to be aligned. For example, it may be adjusted to a high tension to provide a strong biasing force if heavy items are expected, but may be configured to a lower tension for a weaker biasing force if light items are expected.

In the apparatus, the biasing arrangement may comprise one variable length element, where the variable length element is attached at one end to a first point at a fixed position relative to the swivelling element and at the other end to a second point at a fixed position relative to the support element. For example, the variable-length element may be one of a coiled spring, a gas spring, an actuator or an elastic element. The second point may be provided on the support element. Using a variable length element can help urging the swivelling element toward the receiving position. Also, several variable length elements may be used to achieve the desired biasing amount depending on the swivelling element's position relative to the receiving position.

The swivelling element may be arranged to swivel in either direction from the receiving position of the rotation shaft. Such an arrangement may be advantageous for example if the apparatus is to be used with a conveyor that may be used to carry items in two opposite directions.

The alignment apparatus may further comprise rotator arranged to rotate the rotatable element about the axis of the rotation shaft, where the rotator may be in a fixed position relative to the swivelling element and/or relative to the support element.

Using a motor to rotate the rotatable element may be used for improving the "soft embrace" effect, for example with a rotatable element rotating in the same direction as the received item.

The rotator may comprise a motor unit for outputting a mechanical force and force transmitter arranged to transmit the mechanical force to the rotation shaft to cause rotation thereof. For example, the force transmitter may comprise at least one of: a pulley and belt arrangement; a sprocket and chain arrangement; variable conical drives; or a cog wheel arrangement. Using such a motor and force transmitter may facilitate the positioning of the motor, for example on the support element or at a remote location whilst allowing the transmission of the motor's mechanical power to the rotatable element.

The support element may comprise bearings for mounting the swivelling element.

Bearings may be suitable for allowing a strong support of the swivelling element whilst allowing swivelling of said element and whilst providing rigidity in the swivelling element mounting thereby reducing the risk of instability in the apparatus.

The support element may comprise a lower support portion, and the swivelling element may be mounted on top of the lower support portion. Also, the support element may comprise an upper support portion, and the swivelling element may be mounted on and suspended from the upper support portion. The swivelling element may for example be mounted on top of a floor mounted structure. In such an arrangement, the rotatable element may also be hanging above for example a conveyor belt. The swivelling and rotatable elements may also be mounted on a ceiling or bridge element. In another example, the swivelling and rotatable elements may be mounted in the middle of a support element such as a pillar.

The apparatus may further comprise a bearing, wherein the bearing is mounted at a lower part of the rotation shaft. Such a bearing may be used for example for supporting the shaft while allowing said shaft to rotate and/or swivel.

The support element may comprise two protruding brackets, each bracket having a hollow part for receiving the rotation shaft. Such a support element may provide a strong hold on the rotation shaft whilst reducing the risk of buckling.

The apparatus may further comprise a guide member, wherein the guide member comprises an elongate slot for receiving the rotation shaft and for guiding the rotation shaft swivelling between the receiving and opened positions. Providing such a member may improve the rigidity of the apparatus and for example reduce the risk of buckling and/or of damage to the apparatus that may be caused by for example a big and heavy item.

The rotation shaft may be mounted on the swivelling element using one or more load bearings. Load bearings may be suitable for allowing a strong support of the rotation shaft whilst allowing rotation of said element and whilst providing rigidity in the rotation shaft mounting thereby reducing the risk of the rotation shaft buckling.

The support element may comprise a receiving position adjuster for adjusting the receiving position of rotation shaft. For example, receiving position adjusting means may comprise at least one of a cam base and a stud arrangement; and a swivelling motor operable to control the swivelling of the swivelling element. For example, if the apparatus is used in combination with item detection means, it may be useful to for example control the home position of the rotation shaft and swivelling element depending on the items to come. If for example aligning items of very different sizes, the swivelling element may be controlled to be closer to the desired item alignment position for small items, whilst it is further away from said position for large items.

Such an apparatus could then be used in different types of situations by adjusting the receiving position. In another example, e.g. in a mail package distribution centre, a conveyor may be used with small items one day and with large items another day.

By adjusting the receiving position of the apparatus, the apparatus's efficiency may be maintained thereby having for example a possible situation where the apparatus may be well adapted to align small item but becomes less efficient when aligning larger items.

According to a second aspect, there is provided an alignment apparatus arrangement, the arrangement comprising an alignment apparatus and a further alignment apparatus. Using two or more alignment apparatus may provide efficiency for aligning items, for example in the centre of a conveying path.

According to a third aspect, there is provided a conveyor system for positioning and/or aligning an item conveyed by a conveying mechanism. The system comprises a conveying mechanism for conveying an item on conveying path from a first point to a second point, the conveying mechanism having a bearing surface for placing items to be conveyed onto and having, from a top view, a right side and a left side relative to the conveying path along the travelling direction from the first point to the second point; and an alignment apparatus. The apparatus is arranged such that, in the receiving position and in use, when the rotatable element of the alignment apparatus rotates, at least part of the outer flexible portion enters a conveying zone above the bearing surface of the conveying mechanism.

In the conveyor system, the alignment apparatus may be positioned such that the rotation shaft of the apparatus is closer to the centre of the conveying path in the receiving position than in the opened position. Thus, the biasing element of the apparatus will help keep the item on the conveying path whilst aligning said item on the path.

The system may be such that, in a zone around the alignment apparatus, the conveyor path is substantially horizontal and the rotation shaft of the alignment apparatus is substantially vertical.

In the conveyor system, the alignment apparatus may be arranged to rotate in a clockwise direction in the top view, when said alignment apparatus is on the right side of the conveying path; and rotate in an anti-clockwise in the top view, when said alignment apparatus is on the left side of the conveying path. When rotating in such direction, the rotatable element of the alignment apparatus will then rotate in the same direction as the conveying direction and will therefore gently push items in the conveying direction at the same time as it pushes the items toward their aligned position.

The conveyor system may further comprise a second alignment apparatus, wherein the second alignment apparatus is arranged such that, in use, when the rotatable element of the second apparatus rotates, at least part of the outer flexible portion enters the conveying zone; the first alignment apparatus is on the right side of the conveying mechanism; and the second alignment apparatus is on the left side of the conveying mechanism. For example, the position of the rotation shaft of the second alignment apparatus relative to the conveying mechanism and conveying path may mirror the position of the rotation shaft of the first alignment apparatus relative to the conveying mechanism and conveying path. Using two alignment apparatuses in a mirroring arrangement with respect to the conveying path, may facilitate aligning items at a middle position of a conveyor belt, for example at a centre position or at a one-third / two-third position on the conveyor belt. Each of the first and second alignment apparatuses may have a substantially cylindrical rotatable element.

In another example, each of the first and second alignment apparatuses further may have a substantially conical and/or frusto-conical rotatable element, wherein, optionally, the rotatable element of one of the first and second alignment apparatuses is larger at the bottom part of the rotatable element in a vertical direction; and the rotatable element of the other one of the first and second alignment apparatuses is larger at the top part of the rotatable element in the vertical direction. Using two substantially conical alignment apparatuses, where one cone has its base at the bottom and the other one has its base at the top facilitate the tilting of upward-stand ing items to their side.

Also, the system may comprise a plurality of alignment apparatuses, wherein the plurality of alignment apparatuses is on one of the left or right side of the conveying mechanism; and the distance between the centre of the conveying path and the rotation shaft of each of the alignment apparatus in the plurality of alignment apparatuses decreases in a downstream direction with respect to the conveying path.

Using a progressive arrangement of alignment apparatuses, a conveyed item may be aligned in the desired position step by step. Such an arrangement may therefore reduce the risk of an item being completely out of alignment causing problems in the operation of the system. In effect such an item would be gradually aligned to the desired position.

The conveying mechanism may comprise one of a rolling-balls arrangement; or a rollers arrangement.

Also, the conveying mechanism may comprise a conveyor belt, wherein the conveyor belt optionally comprises a plurality of sub-belts. The belt may comprise strengthening means on at least a side portion of the belt. For example, the strengthening means may comprise a protective coating layer and/or film on at least the side portion of the belt; and/or a strengthening material in the belt material on at least the side portion of the belt; and/or an increased thickness in at least said side portion of the belt. The strengthening material may be beneficial to help reducing wear on the belt due to the use of the alignment apparatus.

The alignment apparatus comprised in the system may be arranged to have a lower part of the outer flexible portion of the rotatable element thereof in a close proximity to the top surface of the conveying mechanism. By positioning the rotatable element close to the top surface of the conveying mechanism, the risk of having loose elements (for example bag straps) being trapped on side elements of the conveying mechanism (for example a side-guard) is reduced.

For example, the alignment apparatus of the system may include bristles on a lower region of the outer flexible portion, wherein, in use, when the rotatable element of the alignment apparatus rotates in the receiving position, at least some bristles on said lower region brush the top surface of the conveying mechanism. Having bristles brushing the top surface of the conveying mechanism also reduces the risk of loose elements being trapped on side elements of the conveying mechanism, or falling from the conveyor.

The swivelling element of the alignment apparatus may be substantially parallel to the top surface of the conveying mechanism. As a result, as the swivelling member swivels, the rotatable element of the alignment apparatus remains at the same vertical distance to the top surface.

The support element of the alignment apparatus may, with respect to the conveying path, be in an upstream position relative to the roller element of said alignment apparatus. In such an arrangement, the swivelling element may then rotate in the same (clockwise or anti-clockwise) direction as the rotatable element when aligning an item, thereby providing for a smoother operation of the system.

The system may also comprise a security element arranged to stop operation of the conveying mechanism upon detection of an error. The system then comprises a set of one or more alignment apparatuses, each alignment apparatus comprising an opened position stopper and a corresponding proximity sensor as described above.

Each proximity sensor is operable to send a proximity signal to the security element when the swivelling element of the alignment apparatus is near the corresponding opened position stopper. The security element is operable to stop operation of the conveying mechanism upon reception of a proximity signal for each of the alignment apparatuses in the set of one or more alignments apparatuses. Thus, when a conveyed item causes all alignment apparatuses in a set of alignment apparatuses (for example a pair of apparatuses mirroring each other) to be in a fully opened position, the security element can halt operation of the conveying mechanism for example to avoid damage to the alignment apparatuses or to check the item is of an allowable size.

The system may further comprise a side guard on a portion of the left and/or right side of the conveyor for reducing the risk of an item falling off the top surface, wherein the alignment apparatus is placed at a position between the side guard and the conveying path. For example, the side guard may have a radius-profile for receiving the rotatable element of the alignment apparatus. Such a side guard can therefore accommodate the alignment apparatus and its shape may also follow the conveyor's and alignment apparatus's edges.

The side guard may also comprise a comb-like and/or a flexible lamina arrangement in a downstream and/or an upstream direction with respect to the conveying path and relative to the rotatable element of the alignment apparatus, the comb-like and/or flexible lamina arrangement being for reducing the risk of items entering a zone between said rotatable element and said side guard. As the rotatable element rotates when an item is aligned by the apparatus, any loose element may enter a zone between the rotatable element and the side-guard, which in turn is likely to cause the loose element to wrap around to rotatable element. The comb-like and/or flexible lam ma arrangement reduces the risk of such a problem occurring.

The system may also comprise a security proximity sensor for sensing objects entering a zone near the rotatable element of the alignment apparatus and outside of the conveying zone. Thus if any object is detected in an area around the rotatable element but outside of the conveying zone, the sensor can detect such an object and the necessary steps may be taken (stopping operation, sounding an alert, etc.).

Brief description of the figures

Specific embodiments will now be described by way of example with reference to the following drawings, where like parts are referred to using like numbers: Figure 1 is schematic plan view representation of a conveyor system; Figures 2A and 2B are schematic representations from a perspective view and from a sectional side view of an example roller; Figure 3 is a schematic plan view of an example alignment apparatus; Figure 4 is a schematic side view of an example alignment apparatus; Figures 5A, SB and SC are schematic views of a portion of an example alignment apparatus from a first side, a plan view and a second side opposite said first side; Figures 6A, 6B and 6C are schematic representations of possible outputs of an example proximity sensor; Figures 7A, 7B and 7C are schematic representations of an example circuit for control and/or monitoring a two-alignment apparatus arrangement, where the circuit is represented for three different situations; Figure 8 is a schematic representation of an oversize item which may cause the circuit of Figure 7 to trigger an alert; Figures 9A to 9F are schematic representations of an item being aligned by an example conveyor system; Figure 10 is a schematic plan view representation of an example conveyor system comprising one alignment apparatus; Figure 11 is a schematic plan view representation of an example three-alignment apparatus arrangement relative to a conveyor; Figure 12 is a schematic plan view representation of an example six-alignment apparatus arrangement relative to a conveyor; Figures 1 3A to 1 3D are schematic representations of examples of rotatable elements shapes; Figure 14 is a schematic representation of an example two-alignment apparatus system; Figure 15 is a schematic representation of an example rotatable element comprising bristles; Figures 16A is a schematic representation an example rotatable element from a lateral view; Figures 16B and 16C are schematic representations of the rotatable element of Figure 1 6A from a cross-sectional view along A-A of Figure 1 6A; Figures 17A and 17B are schematic representations of an example alignment apparatus comprising a cog wheel arrangement from, respectively, a side view and a cross-sectional view along B-B of Figure 1 7A; Figure 18 is a schematic plan view representation of an example alignment apparatus; Figure 19 is a schematic representation of the support and swivel elements of an example alignment apparatus; Figure 20 is a schematic representation of an example alignment apparatus comprising a bridge support element; Figure 21 is a schematic representation of an example alignment apparatuses mounted on a conveyor; Figure 22 is a schematic representation of an example alignment apparatus comprising a guiding member; Figure 23 is a schematic representation of a conveyor system having at least three belt sections and an example alignment apparatus; Figures 24A, 24B and 24C are schematic representations of example conveyor systems comprising an alignment apparatus and a side-guard on the same side of the conveyor; Figure 25 is a schematic representation of an example side-guard arrangement for accommodating an alignment apparatus; Figure 26 is a schematic representation of two example alignment apparatuses; Figures 27A, 278 and 27C are schematic representations of a rotatable element manufacturing method; Figures 28A, 28B and 280 are schematic representations of another rotatable element manufacturing method; and Figures 29A, 29B and 29C are schematic representations of a further rotatable element manufacturing method.

While the invention is susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and are herein described in detail. It should be understood, however, that drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

Detailed description

A first embodiment of a conveyor system is illustrated in Figure 1, where the conveyor system 50 has a conveyor belt 51 and is provided with two alignment apparatuses 100 and 200 for alignment items on the conveyor belt 51. In this example, the system is configured to provide centralising and aligning of baggage conveyed on and by the belt and the two alignment apparatuses 100 and 200 are of similar constructions, each one mirroring the other one. Thus, in the interest of conciseness, only the alignment apparatus 100 will be described in detail and the description of any part of alignment apparatus 100 will also apply to the mirroring part of alignment apparatus 200.

The alignment apparatus 100 comprises a rotatable element, or roller, 110, mounted on a rotation shaft 111 and rotatable about the axis of said shaft. In this example, the roller 111 is in the form of a cylindrical brushes rotating about a vertical axis. The roller 110 can rotate in the directions indicated by arrow R1 and about an axis AR1.

The shaft 111 of the roller is mounted on a swivelling element 120 where, in the present example, the swivelling element is an arm 120 which is pivotably movable and is biased toward a particular position. An example of a suitable swivelling element is a spring-loaded arm. The arm 120 is mounted on a support element 130 for swivelling in directions illustrated by arrow SI and about a swivelling point P1. In this example, the arm 120 is mounted on the support element 130 by means of pivot 121.

The alignment apparatus 200 is placed on the other side of the conveyor belt 51 such that the two apparatuses can more easily align an item at the centre of the conveyor belt 51. In the rest of the description, baggage will be used to exemplify conveyed items to be aligned. However, the invention is not limited to aligning baggage and it will be apparent to the skilled person that it can also be used with other types of items, for example mail packages, card boxes, etc. The hatched parts in Figure I show the two alignments apparatuses in a receiving or home position. This home position is for example the position of the arms and roller when no baggage is being aligned. The non-hatched part shows the apparatuses in a second position where the arm has swivelled from the home position and the rollers are further away from the centre of the conveyor belt, for example because of an article of baggage going through the arrangement. As explained before, the arms and 220 are biased toward a particular position and in this example are biased toward their home position (hatched position in Figure 1).

As an article of baggage, for example a bag, passes between the two-alignment apparatus arrangement, the two arms 120 and 220 will open to let the bag through whilst the biasing means will push the arms, and therefore the bag, toward the centre of the conveyor belt. The more each arm is moved away from its home position, the more it pushes back to tend to return to the home position, i.e. toward the desired alignment position. In other words, in this example, the further the roller 110 is pushed away from its home position, the stronger the push toward the centre of the conveyor belt 51 it exerts on the bag. Thus if a bag arrives out-of-alignment on the conveyor belt 51, for example on a left position relating to its direction of travel, i.e. closer to alignment apparatus 100 than alignment apparatus 200, the bag will then first push the arm 120 of apparatus 100 away from its home position, thereby causing the arm 120 to push the bag back. As the arm 220 offers either no resistance or less resistance to such a bag and as the arm 120 pushes the bag back, the bag will move closer to the centre of the conveyor belt. As the bag moves closer to the centre of the conveyor belt 51, the resistance of the arm 120 of apparatus 100 will decrease whilst the resistance of the arm 220 of apparatus 200 will increase, thereby tending to locate the bag in a central position on the conveyor belt 51 and reducing the risk of the bag being pushed to an out-of-alignment position on the right of the conveyor belt 51. Therefore the combined actions of the two arms will move any passing bag toward the centre of the conveyor belt.

The roller 110 of the alignment apparatus 100 of Figure 1 is illustrated in Figures 2A and 2B. On the rotation shaft 111 of the roller 11 0 is a core 112 of hard rubber-like material to which bristles 113 are bonded. The bristles of this example comprise two layers: an inner layer 113a of bristles and an outer layer 113b of bristles where all bristles are flexible and the bristles in inner layer 1 13a are stiffer than the bristles in outer layer 11 3b. Using such an arrangement, the apparatus's opposition to an out-of-alignment bag may be further improved using not only the arm but also the roller.

In effect, the bag will first be received by the softer outer layer of bristles 11 3b for a smooth reception of the bag by the rollers. Items received by such an arrangement are therefore controlled and received by the soft grip of the outer softer bristles whilst the stiffer inner bristles provide a stronger and firmer grip. This soft reception helps avoiding spinning the bag out of control, as may sometimes happen with bags lying on a convex side. In effect when such bags Jying on a convex bag are handied without care, they may spin around the point where the convex side contacts the conveyor belt. The soft embrace reception of items by the rollers reduces the risk of such bags spinning out of control whilst it still providing for the positioning and aligning of items.

If however the bag (any bag or any item) pushes the roller further, for example because it is not aligned and therefore pushes one of the rollers more than the other, the bag will push the stiffer bristles of inner layer 11 3a. This stiffer bristles layer 11 3a is more resilient than the outer layer 113b and will thus offer more opposition to the bag pushing the roller, thereby helping moving the bag to an intended aligned position. In other words, the outer layer 113b helps with the cushioning and smooth handling of the bag whilst the inner layer 1 13a facilitates the alignment of the bag.

Also, the roller comprises a lower portion of bristles 114 where the bristles are directed downwardly. In this example and in use, the roller is positioned such that the lower portion of bristles 114 brushes the conveyor belt to avoid any loose element falling or being trapped between the roller and the conveyor. Examples of methods for manufacturing a rotatable element comprising bristles are discussed below.

In this example, the rollers are rotated using a motor 140 and a pulley and belt arrangement as force transmitter for transmitting the mechanical force from the motor to the rotation shaft 111 to rotate the shaft 111 and thus rotate the roller 110.

Figures 3 and 4 show top and side views, respectively, of apparatus 100 of Figure 1.

In this example, the motor 140 is mounted on the arm 120 and thus swivels with said arm. The mechanical force outputted by motor 140 is transmitted to the rotation shaft using pulleys 141 and belts 142. In particular, some of the pulleys 141 are fixed to the rotation shaft 111 thereby rotating the shaft as they rotate. As can be seen in Figure 4, the shaft 111 of alignment apparatus 100 of Figure 1 is mounted on two brackets 122 and 123 of the support element 130, using a load bearing 171 on each of the brackets. Such an arrangement provides a strong support to the shaft 111, whilst allowing rotation of the shaft and reducing the risk of the shaft buckling. In use, the roller 110 can therefore be rotated such that it facilitates the travelling of bags in the direction of travel (e.g. direction "D" in Figure 1). For example, in Figure 1, roller 110 on the left side of the conveyor belt 51 with respect to the travelling direction D would therefore rotate in an anti-clockwise direction whilst roller 210 on the right side would rotate in a clockwise direction.

The alignment apparatuses 100 and 200 of Figure 1 include stoppers and proximity sensors for controlling and/or monitoring the position of their respective swivelling arms 120 and 220. Figures 5A to SB illustrate the stopper and sensors arrangement of alignment apparatus 100 of Figure 1, bearing in mind that in the example of Figure 1, apparatus 200 mirrors apparatus 100, as explained above. The arm 120 is biased toward its receiving or home position. The biasing of the present example is provided by a spring arrangement including a coiled spring 155 attached to one end to a point 151 fixed relative to the swivelling arm and at the other end to a point 152 fixed relative to the support element 130. As can be seen in Figures SA to 50, in the example of Figure 1, the apparatus 100 also includes a "home" stopper 161 arranged to stop the arm 120 from swivelling further than the home position, and a "opened" stopper 162 arranged to stop the arm 120 from swivelling further than the opened position. In this arrangement, the attachment point 152 of the spring 155 is also on the home stopper 161. Also, the opened stopper 162 includes a proximity sensor 165 for sensing when the arm 120 is near the stopper 162. The stopper may for example be positioned such that the arm does not swivel further than a position that may cause damage to the apparatus and the proximity sensor may help detect when the arm is near the stopper, thus when the arm 120 is near a position possibly where damage could possibly be caused to the apparatus.

A proximity sensor is a device that detects when an object is near the sensor and sends a signal in response to this detection. Examples of possible signals from a proximity sensor are illustrated in Figures 6A to 60, where the illustrations are possible and non-exhaustive examples of outputs from a proximity sensor. In Figure 6A the signal varies from 0 to 1, where 0 means that no object is near the sensor and 1 means that an object is near the sensor. The signal of Figure 6A is set to 1 if an object is at less than a distance d1 to the sensor and to 0 if the object is farther from the sensor than the distance d1. For example, the sensor 165 may be configured to send a signal in response to the detection of the arm near the sensor when the arm has swivelled for at least 90% of the travel from the home position to the opened position, or at least 95% of the travel, or any other suitable value. The sensor 165 may also be configured to send a signal that the arm is near the sensor when the arm is at less than a predetermined distance from the sensor, for example 10cm, Scm, 1cm, or any other suitable distance.

In the example of Figure 6B, the sensor does not send any signal if the object is farther than distance d1 from the sensor. The signal then increases to "1" in a linear manner until the object is at distance d0 to the sensor. If the object is at less than distance do to the sensor, the sensor then outputs a "1" signal. In one further example, the distance d0 may be zero. In the example of Figure 60, the signal varies in a non-linear relation with respect to the distance of the nearest object. For example the signal may vary in a hyperbole or hyperbole-like relation. As for Figure 6A, sensors having an output as illustrated in Figures 6B and 60 may be configured to send a signal having at least a certain value when the arm 120 is at at least a certain distance from the sensor, where the distance may be configured as an absolute value (e.g. Scm) or a relative value (e.g. 95% of the arm travel).

The signals from the sensors may be used to monitor the system, in particular, if the sensor is positioned at an opened stopper for preventing any damage that may occur if the arm swivels further the opened position. An example of a simple circuit that can be used in combination with the proximity sensor 165 of alignment apparatus and with the corresponding proximity sensor 265 of alignment apparatus 200 is illustrated in Figures TA -7C. The circuit includes two power supply lines Ii and 12, where II is the power supply for the conveyor belt 51 (or part of it) and 12 is a power supply for a Programmable Logic Controller (PLC), where the PLC generally controls operation of the conveyor and possibly other of other systems (conveyors or else) and may also be involved in or in charge of the monitoring of the conveyor. The circuit comprises two main switches SW1 and SW2, where SW1 is the main switch associated with alignment apparatus 100 and SW2 is the main switch associated with alignment apparatus 200. The switches SWI and SW2 include two sub-switches SWI A and SW1 B, and SW2A and SW2B, respectively, where each of the sub-switches in a main switch are in an opposite state. In the example of Figure TA, the sub-switches SW1A and SW2A are both closed whilst the sub-switches SW1B and SW2B are both open. This configuration corresponds to "normal" situations where none of the proximity sensors 165 and 265 have detected that the corresponding arm is near the sensor. In other words, none of the arms 120 and 220 is being pushed by an item to its opened position. In that case, the current goes through both SWIA and SW2A sub-switches and to conveyor's supply. At the same time, sub-switches SW1 B and SW2B are open and prevent the current from power supply line 12 to go to the PLC. The arrows in Figure TA (and 7B-7C) illustrate the travelling path of the current in the circuit.

In the example of Figure TB, the sub-switches SW1A and SW2A are both open whilst the sub-switches SWI B and SW2B are both closed. This configuration corresponds to "detection" situations where both sensors 165 and 265 have detected that the arms 120 and 220, respectively, are near the corresponding proximity sensors. Such a configuration may thereby occur when an oversized item is travelling on the conveyor. When both when switches SW1 and 5W2 are in "detection" configuration as shown in Figure TB, the current from power supply line II can not go through the switches SWIA and SW2A and the conveyor is therefore not supplied any power and it stops. Thus any oversized item on the conveyor is stopped from moving further in direction D (see Figure 1) and may therefore be prevented from causing damage (or more damage) to the alignment apparatuses. Also, in the example of Figures TA-TC, a second power supply line 12 is provided for the PLC. In the situation of Figure TB, the power from 12 can be transmitted to the PLC such that the PLC is aware that both arms are in or near their respective opened positions. This can be used for example for the purpose of back indication.

In the example of Figure 70, the main switch SWI is in normal position (SWIA closed, SW1 B open) and the main switch SW2 is in detection position (SW2A open, SW2B closed). This may correspond for example to a situation where an item arrives on the conveyor belt 51 on the right side, i.e. on the side of the alignment apparatus 200 and pushes the arm 220 to its opened position but does not push the arm 120 of apparatus 100 to the same extend. In such a situation, the item is currently being aligned and it is therefore not preferable to stop the conveyor. For example, the item might have arrived with its length at an oblique angle to the travelling path and direction D and might be currently rotating to have its length substantially aligned with the travelling path. In such an example situation, it is in effect preferable to let the conveyor continues with the conveying of items through the alignment apparatuses.

The circuit of Figures 7A-7C can achieve that and can supply power to the conveyor when only one of the arms 120 or 220 is in opened position. As said before, Figure corresponds to a situation where arm 220 is in or near its opened position and the other arm 120 is not. In that case, the power from power supply line Ii can go through sub-switch SWIA and reach the conveyor, whilst the power supply from the power supply line 12 can go through sub-switch SW2B to the PLC such that the PLC is aware that the arm 220 is in (or near) its opened position.

Therefore, with the circuit of Figures 7A-7C, the conveyor's power supply is only cut when both arms 120 and 220 are in (or near) opened position as detected by the proximity sensors 165 and 265, and the PLC can monitor the arms with regard to the opened position. Figure 8 shows an example of a situation that may cause both main switches SW1 and SW2 to be in a "detection" configuration, where an oversized item is placed on the conveyor belt 51 and sent through the alignment apparatuses arrangement.

In another example, the conveying of items may be slowed down when the arm(s) is(are) at a specific first position and, optionally may be stopped when the arm(s) is(are) at a specific second position, further away from the home position than the specific first position.

There has therefore been provided an security arrangement for controlling and/or monitoring operation of the alignment apparatus with a view to reducing the risk of the apparatus being damaged, for example by oversized items.

Figures 9A-QF show, step-by-step, the alignment of an item, for example a bag, going trough the arrangement of Figure 1, where some parts have been omitted for clarity purposes.

Figure 9A shows a situation where an item 10 is conveyed by the conveyor belt 51 and is approaching a two-alignment apparatus arrangement comprising apparatuses and 200 where the rollers 110 and 210 are rotated in directions Dl and D2, respectively. The bag is initially in an uncontrolled position on the conveyor belt 51 before it arrives near apparatuses 100 and 200. In Figure 9B, the item 10 arrives at the two apparatuses 100 and 200 and first contacts the two outer bristles layers 11 3b and 21 3b of rollers 110 and 210, respectively. The softer outer bristles of the rotating rollers provide a "soft-embrace" to item 10.

As item 10 moves further in direction D, it pushes the arms away from their home positions: arm 120 moves in direction D10 and arm 220 in direction D320 as shown in Figure 90. Also, item 10 may contact the stiffer bristles of inner bristles layers 11 3a and 21 3a of rollers 110 and 210, respectively, which will facilitate the alignment of the bag on the conveyor belt by being more resilient and by therefore providing a stronger opposition to the item 10 being out-of-alignment. Also, because the more the item 10 pushes the arms 120 and 220 away from the home positions, the more resistance the arms provide, the system facilitates the item going through the arrangement with its length substantially parallel to the travelling direction, whilst it will offer more resistance to the item going through the arrangement with its length perpendicular to or at an oblique angle relative to the direction of travel. As can be seen in Figure 9D, as the item passes through the rollers 110 and 210, the action of the bristles of outer flexible portion of the rollers and of the biasing arrangement of the corresponding arms 120 and 220 tends to move to bag 10 closer to a position where its length is substantially parallel to the direction of travel D and where (due to the specific and symmetric arrangement of apparatuses 100 and 200 in the present example) it is at a central location on the conveyor belt 51.

As the item 10 goes through the alignment apparatuses (Figure 9F), the combined actions of the biasing means on each of arms 120 and 220 and of the flexible rollers and 210, moves item 10 toward a central position on the belt and with its length in the direction of travel. In Figure 9F, the item 10 has gone through apparatuses 100 and 200, and the arms 120 and 220 of the apparatuses have swivelled back in directions D311 and Ds21, respectively, to their receiving or home positions. The apparatuses 100 and 200 are ready to receive any further item.

There has therefore been provided an alignment apparatus and a corresponding conveyor system for aligning and/or positioning items on a conveyor, where the item are received by one or more alignment apparatuses and the one or more alignment apparatuses which is arranged to align and/or position conveyed items toward a desired position on the conveyor, for example the centre of the conveyor, and toward a desired alignment relative to the conveying direction, for example toward the items having their length substantially parallel to the conveying direction.

As the skilled person will understand, the invention is not limited to this particular example which serves as an illustration. Some (but not all) aspects are discussed below.

In the example above, the conveyor system 50 comprised two alignment apparatuses, however the invention is not limited to two-apparatus arrangement. For example the conveyor system 50 may include only one apparatus 100, as illustrated in Figure 10. In this example, the conveyor system 50 comprise a bearing surface 52, one alignment apparatus 100 on the left side of the conveying path with respect to the direction of travel D, and a side guard 20 on the right side of the bearing surface 52. In this example, the bearing surface narrows and the side guard follows the edge of the bearing surface. In an alternative example, the bearing surface may remain of constant width and the guard be provided extending over the bearing surface to narrow the available bearing surface width. In use, when an item 10 is conveyed on the conveyor, it may contact the side guard 20 as the bearing surface narrows and it may therefore be in an un-aligned position after the funnel-like part of the conveyor due, for example, to falling, tipping or rolling over on the bearing surface or bouncing on the sideguard. Providing an alignment apparatus 100 may therefore facilitate the passage through this funnel-like part by, for example, reducing the likeliness of the item bouncing on the side-guard, and/or by aligning the item on the narrower part of the bearing surface 52. There may also be other situations where a one-alignment apparatus arrangement is suitable, for example, a turn in the conveying path, and the use of a one-alignment apparatus arrangement is not limited to the example illustrated in Figure 10.ln a further example, the conveyor system 50 may comprise more than one or two apparatuses, for example three (see for example Figure 11) or more alignment apparatuses. In the example of Figure 12, the conveyor system comprises a six-alignment apparatus arrangement where the apparatuses are arranged in pairs (100 and 200, 300 and 400, 500, and 600) and where the distance between the rollers in a pair reduces in the travelling direction D. Such an arrangement may for example be advantageous when aligning heavy items where the alignment may be performed in three successive stages whilst reducing the risk of damage to the alignment apparatuses due to the alignment of heavy items.

In other words, any suitable arrangement of apparatuses may be used for aligning items.

There can therefore be provided an alignment apparatus for aligning and/or positioning items conveyed on a conveyor; and/or an arrangement comprising one, two or more such alignment apparatuses; and/or a conveyor system comprising one or more alignment apparatuses for aligning and/or positioning items conveyed on the conveyor.

Also, the rotatable element or roller of an alignment apparatus may have any suitable shape. Examples of shapes that may be suitable for some deployments are illustrated in Figure 13A to 13D. The example of Figure 13A corresponds to some extend to the example of Figure 1 where the roller has a substantially cylindrical shape. In the example of Figure 13B, the roller has a substantially conical shape, whilst in the example of Figure 130 the roller has a bulbous shape. In effect, the roller may have any suitable shape, comprising for example any number of concave and/or convex portions, where the shape can be chosen, for example, based on the items to be aligned. For example, the weight, shape and/or type of items may be taken into consideration. Also, any roller shapes may be combined if more than one alignment apparatuses are provided in a conveyor system. For example, Figure 13D illustrates how two substantially frusto-conical rollers may be used in combination. In this example, the rollers have parallel shafts and they are configured so that the frusto-conical shapes are in opposite direction. Such an arrangement may be used for example for laying items on their side on a conveyor belt.

In other examples, the roller of an arrangement apparatus may have its shaft at an oblique angle relative to the conveyor belt, as illustrated in the example of Figure 14.

In this example, the rollers 120 and 220 of two alignment apparatuses are represented where the first one is at an angle Oi with respect to a vertical direction (the conveyor belt being at a horizontal direction), and the second one being at an angle 02 with respect to the vertical direction.

In yet other examples, the rollers may be of different construction to those shown in Figures 2A and 2B. For example, they may comprise an outer layer made of one flexible material, e.g. rubber or foam. In another example, they comprise two outer resilient layers, an outer layer and an inner layer where the inner layer is more resilient than the outer layer (for example two foam layers, the inner foam layer being less flexible/more resilient than the outer foam layer). If the roller comprises bristles, it may comprise a single one layer or multiple layers of bristles. In general, any suitable material and/or combination of materials may be used for the rotatable elements or rollers.

Also, if the roller comprises bristles, they may have any suitable orientation. In one example, the bristles are provided in several directions and in several lengths (see for example Figure 15). In further examples illustrated in the cross-sectional views along A-A of Figure 16A of Figures 16B and 16C, where Figure 16A shows an example rotatable element from a lateral view, the bristles are provided in planes substantially normal to the rotation shaft. In case of oriented bristles as illustrated in Figure 16C, the roller may be positioned such that the bristles facilitate the cushioning and soft embrace of the received items. For example, a roller of any shape and with bristles according to Figure 16C may be advantageously used in apparatus 200 in Figure 1, even though it could also be used in apparatus 100.

There has therefore been provided an alignment apparatus where the rotatable element may have any suitable shape, construction, and position that can for example be tailored to suit the items to be aligned and/or positioned.

In the example of Figure 1, the apparatuses 100 and 200 each comprises a motor (140 and 240, respectively), however an alignment apparatus may be configured to not comprise any motor for rotating the rotation shaft. For example, in one example alignment apparatus, the roller may be configured to not normally rotate and may rotate when an item is being aligned by the apparatus, owing to the item moving in the conveying direction and abutting the roller and therefore possibly causing the roller to rotate.

In some examples, it may be advantageous to have a motor rotating a roller as it can increase the "soft embrace" effect on the conveyed items, in particular if the roller is rotating in a direction that facilitates a conveyed item to move in the travelling direction (e.g. rollers 110 and 210 of Figure 1 rotating in counter-clockwise and clockwise directions, respectively). The roller may also be rotated in the opposite direction if appropriate. For example, if the items to be conveyed are very heavy and difficult to align, it may be found that rotating the roller in a direction that oppose the travelling of the items on the conveyor may facilitate their alignment. Generally, if two apparatus are provided in a conveyor system, one on each side of the conveyor, it may be preferable to have the two rollers in a counter rotating arrangement, such that they mirror each other.

If a motor is provided on an alignment apparatus, any type of motor may be used, for example an electric motor, a combustion engine, etc. Also, the motor may comprise a gearbox unit for example for having an outputted number of rotations per minute within a desired range. A motor may be positioned at any suitable location, for example on the swivelling arm so that it swivels with the arm. In another example the motor may be to a fixed position relative to the support element, or to another element. For example, the apparatus may be mounted on the floor while the motor is suspended from the ceiling.

If a motor is provided, a force transmitter may be provided for transmitting mechanical force from the motor to the rotation shaft to cause rotation thereof. In one example, the motor is directly connected to the shaft and the force transmitter is then providing as attachment means for attaching the motor to the shaft. In another example, the force transmitter is provided as a pulley and belt (or V-belt) and/or as a sprocket and chain arrangement and/or as variable conical drives.

In a further example, the force transmitter is provided as cog wheel arrangement, as illustrated for example in figures 17A and 17B. Figure 17A is a side view of an alignment apparatus and Figure 17B is the corresponding apparatus viewed from a sectional view along line B-B of Figure 17A. The apparatus comprise a roller 110 (represented as cylindrical in this example, however the roller could be of any shape), the roller 110 having a rotation shaft 111 attached to the support 120. The support element in this apparatus comprises a cog wheel which may be engaged to cog wheel 143 from the motor assemble 140. In this example, the apparatus is mounted on a mounting surface and a bearing 115 is provided on the rotation shaft for supporting the shaft whilst allowing it to rotate about its axis and to swivel with the swivelling element, about the swivelling point. In one example, the mounting surface may be a surface on a floor or other surface where the conveyor is placed. In another example, the mounting surface may be a surface on the ceiling from which the apparatus and motor are suspended.

There has therefore been provided a motor and a force transmitter that may be used for rotating the rotatable element of an alignment apparatus and that may be used to contribute to the "soft-embrace" reception of conveyed items by this alignment apparatus (and other alignment apparatuses, if any).

The swivelling element may have any suitable shape and construction and is not limited to the arm and cog wheel of the previous examples. For example, the swivelling element may be of a substantially triangular shape, as illustrated in Figure 18, where an alignment apparatus 100 is shown in its home position. In the example of Figure 18, the swivelling element 120 swivels about point P1 and the biasing means comprises two biasing elements 156, for example gas springs, each of the biasing elements being attached at one end to the swivelling element 120 and at the other end to a point fixed relative to the swivelling point P1. The apparatus 100 also comprises a rotatable element 110 which is rotatable about the axis ARI of the rotation shaft. Such an alignment apparatus may advantageously be used on a conveyor where the travelling direction may be reversed. In effect, because the swivelling element 120 of such an apparatus may swivel in opposite directions, as illustrated with arrows for the swivelling direction Si, it can receive items that push the swivelling element in both swivelling directions from the home position. For example, a conveyor belt 51 has been illustrated on Figure 18 to show an example of how such an apparatus may advantageously position with respect to a bearing surface of a conveyor, where items may be conveyed in directions D or D'. Likewise, if the apparatus 100 comprises a motor, it may be advantageous to be able to reverse the rotation direction of the rotation shaft for adjusting to any change in conveying direction. If the apparatus does not comprise a motor for rotating the rotation shaft, the rotatable element 110 would then automatically adjust to any change in conveying direction by turning in a direction which is induced by items being aligned as they are conveyed.

There has therefore been provided a swivelling element suitable for use in an alignment apparatus where the swivelling element's shape and arrangement may be adjusted depending on factors such as, other elements of the alignment apparatus, intended use of the alignment apparatus, items to be aligned/positioned, etc. Any suitable biasing arrangement may be used for urging the swivelling element and rotation shaft toward the receiving or home position, for example a coil spring, a gas spring, a leaf arrangement, a volute, a piston, an actuator, an elastic element, etc. Also, the biasing arrangement may be adjustable biasing arrangement. For example, in the case of a spring-based biasing arrangement, the resistance that the spring applies to the swivelling element's movement can be set by adjustable tensioners.

The resistance may therefore be adjusted depending on various factors, for example the weight of items (heavier items may require a higher resistance), the conveyor's speed (slower items may required a lower resistance). The biasing arrangement's adjustment may be performed manually and/or automatically. For example, an automatic adjustment may be based on the conveyor current speed and/or on information from an item weighting element.

There has therefore been provided a biasing arrangement for biasing the swivelling element of an alignment apparatus toward a position corresponding to the home position of the rotation shaft of the apparatus.

Also, an alignment apparatus may comprise a home position adjuster arranged to adjust the receiving position of rotation shaft. For example, the home position adjuster may be one of a cam base and a stud arrangement; and a swivelling motor operable to control the swivelling of the swivelling element. By controlling the home position of the apparatus, the apparatus may be configured such that it is in an configuration suitable for aligning expected items to be aligned. For example an alignment apparatus may be used with a first home position on a first day, for example for aligning and/or positioning small items, and with a second home position for a second day for aligning larger items. The second home position may be further away from the conveyor relative to the first home position for the alignment apparatus to accommodate the larger items. A receiving position adjustment may be performed when appropriate and/or convenient. For example it may be performed on an item per item basis, for example with an item detector such as a camera combined with an object detection software, and a swivelling motor connected to the item detector. In another example, it may be performed on a less regular basis, for example every day or every week. In that event, a simple manual adjustment arrangement (e.g. a cam and stud arrangement) may be considered as more appropriate and more cost effective. In a further example, the home position of an alignment apparatus used with a conveyor may be adjusted for adjusting the desired alignment position on the conveyor. For example, the desired alignment position may be adjusted to be on a side of the conveyor by adjusting the home position of the rotation shaft and swivelling element.

Also, the apparatus may comprise a height adjuster arranged to adjust the rotatable element vertical position relative to the bearing surface of a conveyor. This may be used for example to adjust the position of a rotatable element or roller relative to a conveyor such that it is in a close proximity to the bearing surface, regardless of the conveyor it is used with. It may also be used for maintenance purposes, for example for moving the roller further away from the bearing surface for performing maintenance operations on the conveyor belt (or any other conveying means) and/or the roller.

There has therefore been provided an alignment apparatus where the home position of the rotation shaft and/or the height of the rotatable element may be adjusted at any suitable point in time for adjusting the apparatus to, for example, the type of conveyed items to be aligned/positioned, to their conveying speed, to their weight, to the maintenance of said apparatus, etc. In an example, an alignment apparatus may be configured to not comprise any stopper or proximity sensor. With the apparatus of Figure 18 for example, home position stoppers may not be appropriate and, owing to this specific arrangement, the opened position stoppers may not be considered as being appropriate either. For example, if the biasing means prevent the swivelling element from swivelling to a position which may cause damage to the apparatus, such a stopper may be unnecessary. In another example, one or more home position and/or opened position stoppers may be provided. For example, the apparatus of Figure 18 may comprise two opened position stoppers (one for each of the two opposite swivelling directions from the home position), and no home position stopper.

Optionally, any of the receiving or opened position stoppers may comprise a proximity sensor for detecting when the swivelling element is near the stopper.

Some of the uses of a proximity sensor on an opened position stopper have been discussed in the discussion of Figures 5A-5C, 6A-6C, and 7A-7C. A proximity sensor may also be provided in combination with a receiving position stopper, for example for monitoring operation of the apparatus. Also a control and/or monitoring circuit may be provided for only one alignment apparatus, for two alignment apparatuses (see for example Figures 7A-7C), or for any other number of alignment apparatuses.

There has therefore been provided an alignment apparatus with a monitoring and/or controlling arrangement that may be used, for example, to monitor the operation of the alignment apparatus, and/or to control the operation of the apparatus, where the arrangement may also be used to control some aspects of the operation of a conveyor used with the alignment apparatus, for example, to halt the conveying of items when such conveying may cause damaged to the alignment apparatus (e.g. due to an oversize bag).

The support element of an alignment apparatus may be provided at any appropriate location. In one example, the support element is fixed to the floor, e.g. near a conveyor belt. In another example, the support element is mounted on a kart where the kart is movable along a rail arrangement. in that event, the alignment apparatus may be moved along the rail arrangement and may accordingly be positioned at different locations. In another example, the alignment apparatus is fixed to the ceiling (or to a kart on a rail arrangement on the ceiling), above the conveyor. The support element of an apparatus may comprise a lower support member on which the swivelling element is mounted and/or an upper support member from which the swivelling element is suspended and/or a combination of the two. For example, Figure 19 illustrates an arrangement where the swivelling element 120 is mounted on a support element 130 having both a lower portion and an upper portion. The support member is a pillar-like element which is fixed to both the floor and ceiling. In yet another example illustrated in Figure 20, the support element 130 may be a bridge element where the swivelling element 120 is mounted on the bridge element.

Such an arrangement may provide a strong support for the alignment apparatus.

Also, if a second alignment apparatus is provided on the conveyor system 50, the second alignment apparatus may share its support element with the first alignment apparatus. That is, the second alignment apparatus may have its swivelling element mounted on the bridge element 130. In a further example illustrated in Figure 21, an alignment apparatus may be mounted on the support of the conveyor belt 51.

A guiding member may also be provided for example for increasing the rigidity of the apparatus. Figure 22 shows an illustration of a possible guiding member 172 having an elongate slot 173 for receiving the rotation shaft 111. The slot of the present example is curved to facilitate the swivelling motion of the swivelling member and rotation shaft. The slot 173 facilitates the guiding of the rotation shaft 111 as the swivelling member 120 swivels whilst also reducing the risk of the rotation shaft 111 buckling. One or more guiding members may be provided as appropriate, and a guiding member may be shared by two or more apparatuses. For example the member 173 of Figure 22 may comprise a second elongate slot for receiving the rotation shaft of a second alignment apparatus.

Various bearings may be provided in an alignment apparatus where suitable. For example, bearings may be provided on the rotation shaft for mounting the shaft on the swivelling element. In another example, load bearings may be provided at a bottom part of the rotation shaft for allowing the shaft to swivel and/or rotate.

There has therefore been provided a support element for supporting the swivelling element (and the rotatable mounted on the swivelling element via the rotation shaft), where the support element may be of any suitable shape and position relative to the swivelling element and to the conveyor, if any. There has also been provided further supports arrangements such as a guiding member and/or bearings that may be used for improving the support and/or rigidity of the apparatus.

As the rotatable element may be positioned so that it brushes the conveyor on the bearing surface, this may increase wear of the conveyor. If for example rotatable elements brush the sides of the conveyor, it may be advantageous to provide strengthening means for increasing the conveyor's resistance to wear. For example, if the conveyor comprises a conveyor belt said belt may be reinforced on the side.

For example, a protective coating layer and/or film may be provided on at least a portion of the side of the belt. In another example, the belt may comprise a reinforcing material. Suitable reinforcing materials that may be used for the layer or coating and/or for adding to the conveyor's material(s) may be for example nylon or Teflon which are low friction materials and are therefore less sensitive to wear. The belt may also simply have an increased thickness on the side to make up for the increased wear on those parts. Another example is where the alignment apparatus has its own short section of belt so that it can be suitably reinforced and/or thickened without the expense of making a long conveyor so reinforced. Figure 23 shows an illustration of such an arrangement where conveyor's sections 51a and Sic may be conventional conveyor belts and where the belt of section 51 b may have a reinforced belt for accommodating the increased wear induced by the use of rollers 110 and 210. Also, if the conveyor system is provided with a weighting apparatus for weighting the conveyed items, a upstream part of a conveyor belt section (for example section Sib of Figure 23) may provide a suitable location for the weighting apparatus. In Figure 23, a weighting area 40 has been illustrated at an upstream part of the conveyor belt Sib. However, a conveyor having a plurality of belt sections is not limited to a conveyor having a weighting apparatus and/or at that location. Also the conveyor system may comprise two, three, four or more belt sections and is not limited to a three-section arrangement.

There has therefore been provided a conveyor system where the conveyor has been reinforced at least in portions of the conveyor that may experience an increase wear due to the use of one or more alignment apparatuses in the conveyor system.

When using an alignment apparatus with a conveyor system having a side guard on the side of the conveyor, the apparatus may be arrangement such that the rotatable element is placed between the conveyor and the side guard, or the side guard may be interrupted in an area around the rotatable element. Both examples are schematically illustrated in Figures 24A and 24B. In a further example illustrated on Figure 24C, the side-guard has a radius-profile for receiving the rotatable element.

When the rotatable element of an alignment apparatus rotates, it may cause any loose element to get dragged and maybe wrapped around the rotatable element and/or the rotation shaft of the rotatable element. For reducing the risk of that problem occurring, a comb-like arrangement may be provided downstream of the rotatable element, as illustrated in Figure 25. Such a comb-like arrangement is for example suitable for use with for bristle-based rotatable element as the bristles can go through the comb-like arrangement 2i but a loose element (e.g. a bag strap) would not. The comb-like arrangement may also be replaced or be used in combination with a flexible lamina arrangement. A flexible lamina arrangement is for example well suited for use with a rotatable element made of foam or rubber. Also, a comb-like and/or flexible lamina arrangement may be provided upstream of the rotatable element or both upstream and downstream, and aspects such as the rotations shaft's rotation direction and the travelling direction D may be considered when deciding if and where comb-like and/or flexible lam ma arrangements should be placed. For example, if the travelling direction and/or the rotation's shaft are likely to be reversed, it may then be considered appropriate to have a comb-like or flexible lamina arrangement both upstream and downstream of the rotatable element.

In any case, an alignment apparatus may comprise a security proximity sensor for sensing objects entering a zone near the rotatable element of the alignment apparatus and outside of the conveying zone. This sensor could for example be used for detecting any loose element being dragged by and/or wrapped around the rotatable element. If a side-guard is also provided, the sensor could for example be fixed to the side guard in an area around the rotatable element.

There has therefore been provided a sideguard arrangement that may be used in a conveyor system having one or more alignment apparatuses and that may also comprises an arrangement for reducing the risk of loose elements becoming trapped/wrapped and/or for monitoring any such loose elements if trapped/wrapped.

Any type of suitable conveyor mechanism may be used in a conveyor system having at least one alignment apparatus, for example a conveyor having a belt, where the belt may also comprise a plurality of sub-belts. Other suitable conveyors may be conveyors using cylindrical rollers and/or using rolling balls; and/or moving plate conveyors, for example of the type used for airport carousels or for travelators, also called moving walkways. If the conveyor comprises rollers or balls in an area around a rotatable element, they may also be provided with suitable strengthening means, for example a protective coating.

There has therefore been provided a conveyor system that may be used in a variety of situations and environments for aligning and/or positioning items on the conveyor.

An alignment apparatus is not limited to having one rotatable element and/or one swivelling element only and may comprise any number of each. For example, Figure 26 is an illustration of a possible alignment apparatus 100 (and its optional mirroring counterpart apparatus 200) having one swivel element 120 and two rotatable elements 11OA and hUB, the rotatable element having a rotation shaft lilA and 111 B, respectively. In this example, the downstream rotatable element 111 B has been arranged to be closer to the centre of the conveyor belt such that an item would be first aligned by the upstream roller 11OA and then further aligned by the downstream roller 11OB. It will apparent to the skilled person that Figure 26 is merely an example and that any suitable number of and arrangement of rotatable elements and swivelling elements may be used for an alignment apparatus.

There has therefore been provided an alignment apparatus that may comprising one or more rotatable element and/or one or more swivelling elements for aligning and/or positioning items, where the number and arrangement of rotatable and swivelling elements may be adjusted to the situation and/or to provide for a smoother alignment and/or positioning of items.A rotatable element or roller comprising bristles may be manufactured in any suitable way. Three illustrative examples of manufacturing of such a roller are discussed below.

In an example illustrated by Figures 27A, 27B and 270, the roller 110 is manufactured by first bonding bristles 113 to a mat 112b. The mat 112b may comprise an elastic material, for example plastic, rubber, or foam. Figure 27A shows an illustration of a mat 112b with bonded bristles 113. In the example of Figures 27A-27C, a central element 11 2a is provided on the rotation shaft 111, however the skilled person will recognize that this central element is optional and that the manufacturing method could be carried out without this element. The shaft 111 and central element 11 2a of this example are illustrated in Figure 27B. In the next step, the mat with the bonded bristles is rolled onto the central element 11 2a (or shaft 111 if the central element is not provided) with at least some the bristles extending outwardly relative to the shaft. Once the mat 112b has been rolled on the central element 11 2a, there has been provided a method of manufacturing a rotatable element 110 having a rotation shaft 111; a core 112 (including 112a and 112b) comprising an elastic material; and bristles 113 extending outwardly relative to the rotation shaft.

Also, a portion of the mat may be sealed to another portion of the mat, for example a side of the mat 11 2b may be sealed to the other side of the mat so at the join the two sides to form a seal, as can for example be seen in Figure 270. In another example a portion of the mat may overlap with another portion of the same mat and the two overlapping portions may be sealed together. In case there is a mat overlap, after the rolling and optional sealing steps, the bristles 113 may be trimmed to give the roller the desired shape.

In another example illustrated by Figures 28A, 28B and 280, the roller 110 is manufactured using a cage and injecting the core material or materials into the cage.

Figure 28A shows an illustration of a cage 30, where the cage can be opened in two parts 31 and 32. The cage comprises openings for letting bristles through and may be of any desired shape. A rotation shaft 111 is provided with bristles bonded and/or attached to it, as illustrated in Figure 28B. For example, the shaft 111 may have through-hole in a radial direction and the bristles may be placed in said through-holes such that they extend on both sides of the shaft. The cage 30 is then inserted around the rotation shaft 111 whilst at least some of the bristles are arranged to protrude from the cage via the openings in the cage. Such openings could for example be openings covered with flaps that allow bristles to extends through the openings, whilst provided a relative seal for viscous materials for example.

Alternatively, the openings may have a size corresponding to the size of the bristle or bristles to extend through them. Any other suitable opening may be provided on the cage 30.

Once the cage 30 has been placed on the shaft and bristles, as illustrated in Figure 28C, injections inlets 35 are used for injecting the material or materials for making the core of the roller. Such material or materials may comprise at least one elastic material such as plastic, foam or rubber. Therefore, there has been provided a method of manufacturing a roller having an core comprising the injected materials and bristles bonded to the core and extending outwardly from the core. Once the roller is ready, the cage 30 may be removed from the roller by separating parts 31 and 32.

In a further example illustrated by Figures 29A, 29B and 290, the rotatable element is manufacturing using disks stacked on the rotation shaft 111. Figure 29A shows an example of a suitable rotation shaft for use in this further example of roller manufacturing. The rotation shaft 111 comprises a portion lila having a non-circular cross-section. In that example the cross-section of portion lila of the shaft is a square cross section. However, the cross section could have any other shape, for example triangular or substantially circular but with a dent or emboss. Disks 116 are then provided for making the roller. Illustrations of disks 116 are shown in Figure 29B. The disks 116 comprise bristles 113 bonded to a portion for forming the core 112, and a central opening 117, where the central opening has substantially the same shape as the cross-section of portion ill a of the shaft ill. As illustrated in Figure 290, disks 116 may be inserted on the rotation shaft and stacked onto each other so as to form the core 112 and bristles 113 of the roller. The non-circular shape of the shaft's cross section and of the opening 117 encourages the core 112 and bristles 113 to stay in the same position relative to the rotation shaft 111. There has therefore been provided a method of manufacturing a rotatable element having a shaft 11, a core 112 and bristles 113 extending outwardly relative to the shaft.

Optionally, the disks may be bonded to each other, for example by heat or using a bonding agent such as an adhesive. In another example, if a first disk is to be stacked on a second disk, the sides of the first and second disks that will contact each other may have interlocking shapes.

In all examples of manufacturing methods, the core and/or bristles may be manufactured to be of any suitable shape. In one example, the core is substantially cylindrical whilst the bristles are substantially frusto-conical (by for example trimming the bristles). In another example, the core and bristles have the same type of shape, for example two bulbous shapes. In general, the shape of the core and/or bristles may be chosen to suit a possible or intended use for the rotatable element, which might include a use in a rotatable element as discussed above in the discussion of Figures ito 26.

There has therefore been provided methods of manufacturing a rotatable element comprising a core and bristles bonded to the core, where the core comprises an elastic material and where the manufactured rotatable element may be used for example in an apparatus for aligning and/or positioning items.

Claims

CLAIMS1. An alignment apparatus for positioning and/or aligning an item conveyed by a conveying mechanism, the apparatus comprising: a rotatable element comprising a rotation shaft rotatable about a rotation axis, the rotatable element further comprising an outer flexible portion; a swivelling element for mounting the rotation shaft and for swivelling the rotation shaft about a swivel point, the swivelling element being arranged to swivel the rotation shaft between a receiving position and an opened position; a support element for mounting the swivelling element, wherein the swivel point is fixed relative to the support element; and a biasing arrangement for exerting a biasing force urging the rotation shaft toward its receiving position.
2. An alignment apparatus according to claim 1, wherein rotatable element is substantially cylindrical.
3. An alignment apparatus according to any preceding claim, wherein the rotatable element is substantially conical and/or frusto-conical.
4. An alignment apparatus according to any preceding claim, wherein the rotatable elements comprises at least one concave or convex portion.
5. An alignment apparatus according to any preceding claim, wherein the rotation shaft is a solid steel shaft.
6. An alignment apparatus according to any preceding claim, wherein the outer flexible portion of the rotatable element comprises a resilient portion.
7. An alignment apparatus according to any preceding claim, wherein the outer flexible portion of the rotatable element is arranged to exert, relative to the rotation shaft, in response to an inward-directed compression force exerted on a point of compression on the outer flexible portion, an outward-directed force, wherein the magnitude of said outward-directed force increases in an inversely related relation to the distance between said rotation shaft and the point of compression.
8. An alignment apparatus according to claim 7, wherein the magnitude of the outward-directed force increases in at least an inversely proportional relation to the distance between the rotation shaft and the point of compression.
9. An alignment apparatus according to claim 8, wherein the outer flexible portion comprises an inner layer and an outer layer, the outer layer being less resilient than the inner layer.
10. An alignment apparatus according to any preceding claim, wherein the outer flexible portion of the rotatable element comprises bristles.
11. An alignment apparatus according to claim 10, wherein the outer flexible portion comprises bristles on substantially the entire length of the portion.
12. An alignment apparatus according to claim 10 or 11, wherein the outer flexible portion comprises bristles on a lower region thereof
13. An alignment apparatus according to any of claims 10 to 12, wherein said outer flexible portion comprises a core, wherein the core comprises an elastic material and the bristles are bonded to the core.
14. An alignment apparatus according to claim 13, wherein the core is a variable-size core and, optionally, is an inflatable core.
15. An alignment apparatus according to any of claims 10 to 14, wherein the bristles on a peripheral portion of the rotatable element are outwardly-oriented relative to the rotation shaft.
16. An alignment apparatus according to any of claims 10 to 15, wherein the bristles on a peripheral portion of the rotatable element are arranged in planes normal to the axis of the rotation shaft.
17. An alignment apparatus according to any of claims 10 to 15, wherein the bristles on an extremity portion of the rotatable element are oriented at an oblique angle relative to a plane normal to the axis of the rotation shaft.
18. An alignment apparatus according to any of claims 10 to 17, wherein the outer flexible portion comprises an inner layer of bristles and an outer layer of bristles, wherein the outer layer of bristles protrudes outwardly relative to the inner layer of bristles.
19. An alignment apparatus according to claim 18, wherein the inner layer of bristles comprises bristles that are stiffer than the bristles of the outer layer of bristles.
20. An alignment apparatus according to any preceding claim, wherein the outer flexible portion comprises a layer comprising an elastic material
21. An alignment apparatus according to claim 20, wherein the elastic material is foam or rubber.
22. An alignment apparatus according to any preceding claim, the apparatus further comprising a receiving position stopper arranged to stop the swivelling element from swivelling further than the receiving position.
23. An alignment apparatus according to any preceding claim, the apparatus further comprising an opened position stopper arranged to stop the swivelling element from swivelling further than the opened position.
24. An alignment apparatus according to claim 22 or 23, wherein at least one of the receiving position and opened position stoppers comprises a proximity sensor for detecting when the swivelling element is near the at least one of the receiving position and opened position stoppers.
25. An alignment apparatus according to any of claims 22 to 24, wherein at least one of the receiving position and opened position stoppers is provided on the support element.
26. An alignment apparatus according to any preceding claim, wherein the biasing arrangement is an adjustable biasing arrangement for adjusting the biasing force exerted by said biasing arrangement.
27. An alignment apparatus according to any preceding claim, wherein: the biasing arrangement comprises one variable length element; and the variable length element is attached at one end to a first point at a fixed position relative to the swivelling element and at the other end to a second point at a fixed position relative to the support element.
28. An alignment apparatus according to claim 27, wherein the variable-length element comprise at least one of a coiled spring, a gas spring, an actuator or an elastic element.
29. An alignment apparatus according to claim 27 or 28, wherein some of the second point is provided on the support element.
30. An alignment apparatus according to any preceding claim, wherein the swivelling element is arranged to swivel in either direction from the receiving position of the rotation shaft.
31. An alignment apparatus according to any preceding claim, the alignment apparatus further comprising a rotator arranged to rotate the rotatable element about the axis of the rotation shaft.
32. An alignment apparatus according to claim 31, wherein the rotator is in a fixed position relative to the swivelling element.
33. An alignment apparatus according to claim 31 or 32, wherein the rotator is in a fixed position relative to the support element.
34. An alignment apparatus according to any of claims 31 to 33, wherein the rotator comprises: a motor unit for outputting a mechanical force and a force transmitter t arranged to transmit the mechanical force to the rotation shaft to cause rotation thereof.
35. An alignment apparatus according to claim 34, wherein the force transmitter comprises at least one of: a pulley and belt arrangement; a sprocket and chain arrangement; variable conical drives; or a cog wheel arrangement.
36. An alignment apparatus according to any preceding claim, wherein the support element comprises bearings for mounting the swivelling element.
37. An alignment apparatus according to any preceding claim, wherein the support element comprises a lower support portion, and the swivelling element is mounted on top of the lower support portion.
38. An alignment apparatus according to any preceding claim, wherein the support element comprises an upper support portion, and the swivelling element is mounted on and suspended from the upper support portion.
39. An alignment apparatus according to any preceding claim, the apparatus further comprising a bearing, wherein the bearing is mounted at a lower part of the rotation shaft.
40. An alignment apparatus according to any preceding claim, wherein the support element comprises two protruding brackets, each bracket having a hollow part for receiving the rotation shaft.
41. An alignment apparatus according to any preceding claim, the apparatus further comprising a guide member, wherein the guide member comprises an elongate slot for receiving the rotation shaft and for guiding the rotation shaft swivelling between the receiving and opened positions.
42. An alignment apparatus according to any preceding claim, wherein the rotation shaft is mounted on the swivelling element using one or more load bearings.
43. An alignment apparatus according to any preceding claim, wherein the support element comprises receiving position adjuster for adjusting the receiving position of rotation shaft.
44. An alignment apparatus according to claim 43, wherein receiving position adjuster comprises at least one of a cam base and a stud arrangement; and a swivelling motor operable to control the swivelling of the swivelling element.
45. An alignment apparatus according to any preceding claims, the alignment apparatus being a baggage alignment apparatus.
46. An alignment apparatus arrangement, the arrangement comprising at least an alignment apparatus according to any of claims 1 to 41 and a further alignment apparatus according to any of claims I to 41.
47. A conveyor system for positioning and/or aligning an item conveyed by a conveying mechanism, the system comprising: a conveying mechanism for conveying an item on a conveying path from a first point to a second point, the conveying mechanism having a bearing surface for placing items to be conveyed onto and having a right side and a left side relative to the conveying path along the travelling direction from the first point to the second point; and an alignment apparatus according to any of claims I to 44, wherein the apparatus is arranged such that, in the receiving position and in use, when the rotatable element of the alignment apparatus rotates, at least part of the outer flexible portion enters a conveying zone above the bearing surface of the conveying mechanism.
48. A conveyor system according to claim 47, wherein the alignment apparatus is positioned such that the rotation shaft of the apparatus is closer to the centre of the conveying path in the receiving position than in the opened position.
49. A conveyor system according to claim 47 or 48, wherein, in a zone around the alignment apparatus, the conveyor path is substantially horizontal and the rotation shaft of the alignment apparatus is substantially vertical.
50. A conveyor system according to any of claims 47 to 49, wherein the alignment apparatus is arranged to: rotate in a clockwise direction in the top view, when said alignment apparatus is on the right side of the conveying path; and rotate in an anti-clockwise in the top view, when said alignment apparatus is on the left side of the conveying path.
51. A conveyor system according to any of claims 47 to 50, the system further comprising a second alignment apparatus, wherein: the second alignment apparatus is according to any of claims 1 to 44 and is arranged such that, in use, when the rotatable element of the second apparatus rotates, at least part of the outer flexible portion enters the conveying zone; the first alignment apparatus is on the right side of the conveying mechanism; and the second alignment apparatus is on the left side of the conveying mechanism.
52. A conveyor system according to claim 51, wherein the position of the rotation shaft of the second alignment apparatus relative to the conveying mechanism and conveying path mirrors the position of the rotation shaft of the first alignment apparatus relative to the conveying mechanism and conveying path.
53. A conveyor system according to claim 51 or 52, wherein the rotatable element of each of the first and second alignment apparatuses is substantially cylindrical.
54. A conveyor system according to claim 51 or 52, wherein the rotatable element of each of the first and second alignment apparatuses is substantially conical and/or frusto-conical.
55. A conveyor system according to claim 54, wherein the rotatable element of one of the first and second alignment apparatuses is larger at the bottom part of the rotatable element in a vertical direction; and the rotatable element of the other one of the first and second alignment apparatuses is larger at the top part of the rotatable element in the vertical direction.
56. A conveyor system according to any of claims 47 to 55, wherein the conveyor system comprises a plurality of alignment apparatuses, each according to any of claims 1 to 44, wherein the plurality of alignment apparatuses is on one of the left or right side of the conveying mechanism; and the distance between the centre of the conveying path and the rotation shaft of each of the alignment apparatus in the plurality of alignment apparatuses decreases in a downstream direction with respect to the conveying path.
57. A conveyor system according to any of claims 47 to 56, wherein the conveying mechanism comprises one of moving plate arrangement; a travelator arrangement; a rolling-balls arrangement; or a rollers arrangement.
58. A conveyor system according to any of claims 47 to 57, wherein the conveying mechanism comprises a conveyor belt, wherein the conveyor belt optionally comprises a plurality of sub-belts.
59. A conveyor system according to claim 58, wherein the conveyor belt comprises strengthening means on at least a side portion of the belt.
60. A conveyor system according to claim 59, wherein the strengthening means comprises a protective coating layer and/or film on at least the side portion of the belt.
61. A conveyor system according to claim 59 or 60, wherein the strengthening means comprises including a strengthening material in the belt material on at least the side portion of the belt.
62. A conveyor system according to any of claims 59 to 61, wherein the strengthening means comprises an increased thickness in at least said side portion of the belt.
63. A conveyor system according to any of claims 47 to 62, wherein the alignment apparatus comprised in the system is arranged to have a lower part of the outer flexible portion of the rotatable element thereof in a close proximity to the top surface of the conveying mechanism.
64. A conveyor system according to any of claims 47 to 63, wherein the alignment apparatus of the system further include bristles on a lower region of the outer flexible portion according to claim 12; and in use, when the rotatable element of the alignment apparatus rotates in the receiving position, at least some bristles on said lower region brush the top surface of the conveying mechanism.
65. A conveyor system according to any of claims 47 to 64, wherein the swivelling element of the alignment apparatus is substantially parallel to the top surface of the conveying mechanism.
66. A conveyor system according to any of claims 47 to 65, wherein the support element of the alignment apparatus is, with respect to the conveying path, in an upstream position relative to the roller element of said alignment apparatus.
67. A conveyor system according to any of claims 47 to 63, the system further comprising a security element arranged to stop operation of the conveying mechanism upon detection of an error, wherein: the system comprises a set of one or more alignment apparatuses, each alignment apparatus comprising an opened position stopper and a corresponding proximity sensor according to claims 17 and 18; each proximity sensor is operable to send a proximity signal to the security element when the swivelling element of the alignment apparatus is near the corresponding opened position stopper; and the security element is operable to stop operation of the conveying mechanism upon reception of a proximity signal for each of the alignment apparatuses in the set of one or more alignments apparatuses.
68. A conveyor system according to any of claims 47 to 67, the system further comprising a side guard on a portion of the left and/or right side of the conveyor for reducing the risk of an item falling off the top surface, wherein the alignment apparatus is placed at a position between the side guard and the conveying path.
69. A conveyor system according to claim 68, wherein the side guard has a radius-profile for receiving the rotatable element of the alignment apparatus.
70. A conveyor system according to claim 68 or 69, wherein the side guard comprises a comb-like and/or a flexible lam ma arrangement in a downstream and/or an upstream direction with respect to the conveying path and relative to the rotatable element of the alignment apparatus, the comb-like and/or flexible lamina arrangement being for reducing the risk of items entering a zone between said rotatable element and said side guard.
71. A conveyor system according to any of claims 47 to 70, the system comprising a security proximity sensor for sensing objects entering a zone near the rotatable element of the alignment apparatus and outside of the conveying zone.
72. A method of positioning and/or aligning an item conveyed by a conveying mechanism, the method comprising: receiving a conveyed item with a rotatable element, wherein the rotatable element comprises a rotation shaft rotatable about a rotation axis, and further comprises an outer flexible portion, the rotation shaft being in a receiving position when the conveyed item is received by the rotatable element; and in response to a conveyed item pushing the rotatable element: swivelling a swivelling element, wherein the rotation shaft is mounted on the swivelling element and the swivelling element is arranged to swivel the rotation shaft about a swivel point between the receiving position and an opened position; and exerting a biasing force on the swivelling element urging the rotation shaft toward its receiving position.
73. The method of claim 72, the method further comprising: rotating the rotatable element about the rotation axis.
74. The method of claim 73, wherein rotating the rotatable element comprises rotating the rotatable element in a direction that facilitates the conveying of a conveyed item in the conveying direction when the item abuts the rotatable element.
75. The method of any of claims 72 to 74, wherein the method further comprises: receiving the conveyed item with a further rotatable element, wherein the further rotatable element comprises a further rotation shaft rotatable about a further rotation axis, and further comprises a further outer flexible portion, the further rotation shaft being in a further receiving position when the conveyed item is received by the rotatable element; and in response to a conveyed item pushing the further rotatable element: swivelling a further swivelling element, wherein the further rotation shaft is mounted on the further swivelling element and the further swivelling element is arranged to swivel the further rotation shaft about a further swivel point between the further receiving position and a further opened position; and exerting a biasing force on the further swivelling element urging the further rotation shaft toward its further receiving position.the method further comprising: receiving the conveyed item with the rotatable element and the furtherrotatable element.
76. The method of any of claims 72 to 75, wherein the method further comprises: monitoring the position of the swivelling element and rotation shaft; and upon detection that the rotation shaft is in its opened position, deciding whether the conveying of items should be stopped; and in the event that it is decided that the conveying of items should be stopped, sending a stop signal for stopping the conveying of items.
77. The method of operating an alignment apparatus according to any of claims I to 45 for positioning and/or aligning an item conveyed by a conveying mechanism.
78. The method of operating a conveyor system according to any of claims 47 to 71 for positioning and/or aligning an item conveyed by a conveying mechanism.
79. A method of manufacturing a rotatable element having a rotation shaft and an outer flexible portion, wherein the outer flexible portion comprises a core and bristles, the method comprising: bonding bristles to a layer comprising an elastic material; rolling the layer on the rotation shaft such that at least some of the bristles extend, relative to the rotation shaft, outwardly from the layer.
80. The method of claim 79, the method further comprising placing a central element on the rotation shaft and wherein rolling the layer on the rotation shaft comprises rolling the layer on the central element.
81. The method of claim 79 or 80, wherein the method further comprising rolling the layer such that the layer has a substantially ring-shape in cross-section.
82. The method of any of claims 79 to 81, the method further comprising sealing a portion of the layer to another portion of the layer.
83. A method of manufacturing a rotatable element having a rotation shaft and an outer flexible portion, wherein the outer flexible portion comprises a core and bristles and the rotation shaft comprises a stacking portion, the stacking portion's cross section having a specific non-circular shape, the method comprising: inserting a plurality of disks on the rotation shaft and stacking portion, wherein a disk has a central opening of substantially the specific shape, and comprises a core and bristles bonded to the core, the core comprising an elastic material.
84. A method of manufacturing a rotatable element having a rotation shaft and an outer flexible portion, wherein the outer flexible portion comprises a core and bristles, the method comprising: bonding bristles to the rotation shaft; applying a cage about the rotation shaft, wherein at least some of the bristles protrude from the applied cage; injecting the cage with at least one material for making the core, wherein the at least one material comprises an elastic material.