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

A method of sorting items using a system that includes a plurality of delivery vehicles for delivering items to a plurality of destination areas arranged into a series of columns extending generally vertically, wherein the method comprises the steps of:

• conveying items along a path;
• scanning the items with a scanner to identify identification indicia on the items as they are conveyed along the path;
• conveying scanned items from the scanner to the delivery vehicles;
• loading scanned items onto the delivery vehicles;
• determining that one of the scanned items is to be sorted manually rather than by a delivery vehicle;
• identifying the destination area to which the item is to be sorted manually;
• manually conveying the item to the identified destination;
• independently controlling the operation of the delivery vehicles to drive the delivery vehicles to the destination areas to deliver scanned items.

An apparatus for sorting items, comprising

• a plurality of destination areas arranged in a plurality of generally vertical columns;
• a plurality of delivery vehicles for delivering items to the plurality of destination areas;
• an input conveyor for receiving the items and conveying the items toward a loading station;
• a scanner for scanning the items as the items are conveyed toward the loading station, wherein the scanner is configured to scan the items for indicia identifying the items;
• a central controller programmed to independently control the operation of the delivery vehicles to drive the delivery vehicles to the destination areas to deliver scanned items, wherein the central controller is programmed to determine whether one of the scanned items is to be sorted manually rather than by a delivery vehicle;
• and
• a visual signal indicative of the destination area to which the item is to be sorted manually;
• wherein the controller is programmed to control the visual signal in response to determining that one of the items is to be sorted manually.