1. Electronic diagram

The IR-Ranger board doesn't contain lots of components, as shown in the following diagram (only a diode):

 

---

2. Electronic assembly

The following pictures show the implementation of the components on a board:

Reverse side:

 

---

3. Calibration

The GP2D02 IR ranger output its distance measures as a byte. After enabling the ranger, the GP2D02 gives its result as a sequence of 8-bits:

The following chart shows how to convert this byte into a cm distance: The distance accuracy depends on the reflective object material, and other stuffs... Let's say the distance is reliable between 10cm (byte with decimal value ~200) and 80cm (byte with decimal value ~75).

 

In order the robot to provide distances, we have to found the approx. formula of this chart. Taking points on the chart, putting the whole into Excel, gives the following chart:

Now we have the formula: f(x) = (760893/x)^(1/2.1286) . The robot will be able to easily convert its received bytes into human readable distances...