Material handling apparatus and method for automatic and manual sorting of items using a dynamically configurable sorting array

A material handling system for sorting a plurality of items into groups of one or more items, comprising:

• a controller including a processor and memory;
• a plurality of destination areas defined by a rack structure and arranged at a plurality of vertical elevations relative to an underlying floor;
• a plurality of delivery vehicles each configured to move horizontally and vertically to reach any of the plurality of destination areas and each being configured to receive a respective item of a plurality of items and operable to transport the respective item to any destination area of the plurality of destination areas, wherein each delivery vehicle comprises
• a power source for driving the delivery vehicle, and
• a transfer mechanism operative to transfer a received item to a selected destination area;
• wherein the processor is configured to execute instructions, stored in the memory of the controller, to control operation of the plurality of vehicles, and to determine that each respective destination area of the plurality of destination areas has accumulated all items required to form a corresponding complete group of items.

A method of operating a material handling system to sort a plurality of items into groups of one or more items, comprising:

• operating each delivery vehicle, of a plurality of delivery vehicles, to receive a respective item of a plurality of items at an induct station;
• selecting a destination area for each received item of a plurality of received items, from among a plurality of destinations areas, wherein each destination area of the plurality of destination areas is dimensioned and arranged to receive one of the groups;
• operating a first delivery vehicle to transport a received item to a destination area selected for a first group of items, by travel vertically and horizontally from the induct station to a position of alignment with the selected destination area;
• operating the first delivery vehicle to transfer a received item to the selected destination area;
• determining that the selected destination area has accumulated all items required to form a corresponding complete group of items, and
• providing an indication when the selected destination area has accumulated the corresponding complete group of items.