US 12,134,110 B2
Material handling apparatus and method for automatic and manual sorting of items using a dynamically configurable sorting array
John Sauer, Moorestown, NJ (US); Monty McVaugh, Moorestown, NJ (US); Kevin Cherry, Moorestown, NJ (US); and Alexander Stevens, Moorestown, NJ (US)
Assigned to OPEX Corporation, Moorestown, NJ (US)
Filed by OPEX Corporation, Moorestown, NJ (US)
Filed on Dec. 29, 2022, as Appl. No. 18/090,648.
Application 18/090,648 is a continuation of application No. 16/871,774, filed on May 11, 2020, granted, now 11,654,456.
Application 16/871,774 is a continuation of application No. 16/658,849, filed on Oct. 21, 2019, granted, now 10,639,678, issued on May 5, 2020.
Application 16/658,849 is a continuation in part of application No. 15/586,204, filed on May 3, 2017, granted, now 11,607,713.
Application 16/658,849 is a continuation in part of application No. PCT/US2017/050294, filed on Sep. 6, 2017.
Application PCT/US2017/050294 is a continuation in part of application No. PCT/US2017/030930, filed on May 3, 2017.
Claims priority of provisional application 62/331,020, filed on May 3, 2016.
Prior Publication US 2023/0294135 A1, Sep. 21, 2023
Int. Cl. G06F 7/00 (2006.01); B07C 3/00 (2006.01); B07C 3/14 (2006.01); B07C 3/20 (2006.01); B07C 5/10 (2006.01); B07C 5/34 (2006.01); B07C 5/342 (2006.01)
CPC B07C 3/14 (2013.01) [B07C 3/008 (2013.01); B07C 3/20 (2013.01); B07C 5/10 (2013.01); B07C 5/3412 (2013.01); B07C 5/3422 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A material handling system for sorting a plurality of items into groups of one or more items, comprising:
a controller including a processor and a memory;
a rack structure defining a plurality of destination areas at vertically spaced elevations, wherein at least some destination areas of the plurality of destination areas are dimensioned and arranged to receive a container and wherein each container is dimensioned and arranged to receive a corresponding group of one or more items;
an induct station; and
a plurality of delivery vehicles each 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 container disposed at a selected destination area;
wherein the processor executes instructions, stored in the memory, for controlling operation of the plurality of delivery vehicles,
for determining that any destination area of the plurality of destination areas has accumulated all items required to form a corresponding complete group of items, and
for providing an indication when said any destination area of the plurality of destination areas has accumulated a complete group of items.
 
8. 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.