I. Introduction

This document provides specifications for the sensor modification process involved in robot modification to ensure stable product quality and provide guidelines for technical personnel to follow during the modification process.
Robot automation transformation involves a large number of sensors, and it is recommended to use the standard core controller wiring harness TE23 and TE35. This document takes the standard core controller wiring harness as the blueprint for operation guidance.
Note: This document is for reference only and cannot be used as a technical agreement or other content that assumes responsibility.

II. Application Scope

This document is intended for technical personnel who utilize sensors for research and development, production, and installation.

Three, Selection of Sensors

For NPn-normally open type, the output line is suspended when no signal is triggered, meaning that the 0V line and the out line are disconnected. When a signal is triggered, the out line is connected to the 0V line, and the output level is low 0V.
For NPn-normally closed type, the out line is connected to the 0V line when no signal is triggered, emitting the same voltage as the 0V line, and the output level is low 0V. When a signal is triggered, the 0V line and the out line are disconnected, suspending the output line.
The SRC 2000's DI interface only supports NPN logic, not PNP. For functional safety, it is recommended to select an NPN-normally closed sensor. This selection is more secure from a hardware perspective, allowing for the detection of a powered-off sensor or a sensor output signal cable that has fallen off in advance.
The following document uses the Sick GTB10-N1212 photoelectric sensor as an example to explain the transformation.

IV. Transformation Process

4.1 Sensor Status Check

• Proficient in the mechanical and electronic parameters of sensors used in robot modification.
• Expertise in the circuit direction of sensors involved in robot transformation, and ensuring the electrical safety of the entire machine by wrapping exposed live terminals with insulation tape.
• Thorough understanding of the mechanical layout of sensors involved in robot transformation, including sensor installation position and customer-specified sensor installation position.
• Well-versed in the installation position of sensors involved in robot transformation, and ensuring that the installation position is dry, clean, and free from corrosive liquids, gases, iron chips, dust, oil, and mechanical interference.

4.2 Cable Modification Description

1. Determine the working voltage of the product based on the product specifications. For example, the Sick GTB10-N1212 Photoelectric Sensor has a working voltage of 10-30V DC.
2. Refer to the product manual to find the wiring definition.

Photoelectric sensor Sick GTB10-N1212. The wiring diagram is shown in the image. The brown wire should be connected to the positive terminal of the power supply, while the blue wire should be connected to the negative terminal of the power supply. The black cable should be connected to the signal input cable corresponding to DI.

3. Provide comprehensive wiring modification instructions based on the product's operating voltage and wiring definitions. Once the working voltage is turned on, the green LED indicator will illuminate.

4.3 Sensor Debugging

1. The Sick GTB10-N1212 photoelectric sensor has two trigger modes: open and dark pass. These modes can be set by rotating switch 7. Refer to Figure 4.3.1 for more information.

Figure 4.3.1
4.3.2 Level L is open, the output of the photoreceiver is on when it receives irradiation, that is, the sensor is closed when there is reflection of the occluder, that is, the output of the photoreceiver is disconnected when there is no reflection of the occluder, which can be understood as normally on. D is dark pass, the output is on when the photoreceiver does not receive irradiation, that is, the sensor is closed when there is no occluder reflection, the photoreceiver receives irradiation, that is, the output is disconnected when there is occluder reflection, which can be understood as normally closed.
4.3.3 Select the dark pass mode here, that is, rotate switch 7 to D gear.
4.3.4 Conditions of use for confirmation inspection: scan range and distance of correction to object or background, as well as object reflection ability. Diffuse: 6 % = black, 18 % = gray, 90 % = white
(Based on the standard white specified in DIN5033)
4.3.5 Aim the light spot at the detecting object. If the yellow LED indicator continues to light up, it indicates that the photoelectric sensor has detected the object. See Figure 4.3.2.

Figure 4.3.2
4.3.6 Use the potentiometer to adjust the scanning range: Locate the detecting object 0.5m away from the sensor in the middle of the optical path (0.5m is taken as the safe distance here, please adjust it according to the site conditions), and turn the No.6 rotary switch (potentiometer) to the right until the yellow LED indicator continues to light up. Remove the object, the yellow LED indicator goes out, and the adjustment is over.
If the yellow LED indicator is not off or blinking, slowly turn the No. 6 rotary switch (potentiometer) to the left until the yellow LED indicator is off. Reposition the object. If the yellow LED light continues to light up, the adjustment ends. If the object cannot be guaranteed to be detected, check the conditions of use (refer to 4.3.4). See Figure 4.3.3.
Note: Some brands of photoelectric sensors lose their functional effect especially on black detection objects. It is suggested that black detection objects should also be used for testing.

Figure 4.3.3
4.4 Configuration of Roboshop robot model
4.4.1 Open Roboshop robot model device, add DI device, and configure property window id. Please pay attention not to check the box at this time. The following uses DI0 as an example. Figure 4.4.1

Figure 4.4.1
4.4.2 Open Roboshop map and control I/O configuration, and check that the status of DI0 is displayed as green (high level, 1). DI0 in green indicates that the sensor is normally closed. Figure 4.4.2

Figure 4.4.2
4.4.3 Add new DISensor to the Roboshop robot model device according to the product design, and configure the position and function of the sensor in the device attributes. Figure 4.4.3

Figure 4.4.3
4.4.4 For a simple test, place a probe object in the sensor detection area, control the robot to move in the direction of the probe object, and check whether DI achieves the configured function. At this time, two situations may occur: 1. The sensor signal is not triggered and the signal light is not displayed, but the sensor stop state on Roboshop is effective; 2. 2. The sensor signal is triggered and the signal light is displayed, but the sensor stop state on Roboshop is invalid. This anti-logic state was caused by Roboshop adapting to the traditional use habits of various sensors. To eliminate this problem, just check 'inverse' in the device attribute configuration of sensor corresponding to DI in the robot model, and then push the robot model. Control the robot to move in the direction of the detecting object again and check whether DI achieves the configured function. At this time, the sensor signal is not triggered and the signal light is not displayed, and the robot walks normally. When the sensor signal is triggered, the signal light is displayed and the robot stops. As shown in Figure 4.4.4.

Figure 4.4.4
5. Functional testing
Function test is used to judge whether the sensor installation and function is normal (for reference).
5.1 The robot path navigation is controlled through the Roboshop task chain. At this time, the robot path navigation is normal. Then, various detection objects are placed in the sensor detection area of the robot navigation path to check whether the robot sensor has realized the configured function. At this time, the robot has realized the stop function. (Function part)
Note: Some brands of photoelectric sensors lose functional effect on black detection objects, it is suggested to choose black detection objects for testing.
5.2 Disconnect the sensor power and control the robot to walk through the Roboshop task chain. At this time, there is no need to place various detection objects in the sensor detection area on the robot navigation path, and the robot will stop moving, realizing the sensor power failure detection and ensuring the robot's operation safety.
5.3 Manually disconnecting the signal output line of the sensor will also cause the robot to stop moving, similar to 5.2. The detection of the sensor's signal output line falling off is realized. Short circuit of signal output line and power supply can also be detected, but short circuit of signal output line and ground cannot be detected.
5.4 After the test is complete, restore the sensor power supply and signal cable connection to ensure that the sensor works properly.