A lot does not always help a lot - what to look out for when installing PDC sensors.

🛠️ The issue: poor design and manufacturing quality, resulting in significant differences in the distance measured and the angular field.

💥 The consequence: the sensor does not always respond.

So today, let’s take a look at how PDC sensors are constructed in general, where differences in quality can occur, and what to look out for when installing this small but important part.

Structure

PDC sensors usually consist of a decoupling ring, ultrasonic transmitter/sensor, encapsulation/water protection, sensor housing, control board and transformer. So far so good.

What makes a significant difference here, however, is the positioning of the individual components: where the encapsulation/water protection is usually glued to the sensor housing, MEYLE has decided to use a sealing ring instead and place the water protection in front of the ultrasonic transmitter/sensor.

❗ The advantage: water cannot penetrate the PDC sensor as easily, thus making it less prone to failure.

The use of a fixed transformer as opposed to a regulating transformer also has a number of advantages:

Regulating transformers are usually variably adjustable. Although this may have some advantages, it also makes them more prone to destructive interferences. In contrast, fixed transformers – as the name suggests – have a fixed setting at which they operate. This makes them less sensitive to interferences and energy losses and allows them to transfer signal waves with almost no malfunction.

Manufacturing and quality

There are also different levels on the market in terms of manufacturing quality.

Most of the time, a so-called soft soldering process, in which a reflow oven is utilised to solder circuit boards, is used. In contrast, a laser soldering process ensures that all components are soldered automatically, guaranteeing precise connections and a secure electrical connection.

💡 A high-quality, automated process is particularly important for transformers, as manual soldering processes can lead to contact problems.

Needless to say, the paint finish also plays a part in the overall quality of the product. Therefore, PDC sensors from MEYLE are only primed and can be painted to match the colour of the car later on.

... and this is where great attention must be paid! Why, you may ask? Because even a brand-new sensor will only work to a limited extent or not at all if the paint thickness exceeds 120 micrometres.

💡 Our tip: when using a steam jet, keep a minimum distance of 0.5 metres. This minimises the risk of damaging the sensor.

To summarise, it is not only what a PDC sensor looks like that matters, but also what it is made of and how it is made 😉

You can find an overview of the entire range of assistance systems from MEYLE here.