What Are Fuel Level Sensors? Comprehensive Guide 2023

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What Are Fuel Level Sensors? Comprehensive Guide
2023 by Diksha Bhandari Last updated Jun 5,
2023 at 958AM
Discover the world of fuel level sensors and
their potential to take your fleet management to
new heights! Know everything from importance,
applications, and types of fuel monitoring
devices. Table of Contents
Welcome to the fuel-powered adventure! Today,
well dive into the world of fuel level sensors,
the unsung heroes that keep our vehicles up and
running efficiently. Fuel expenses eat up the
maximum budget allotted to a fleet. On top of it,
foes like pilferage, wastage, and leakages make
the overall ride all the more heavy on the
pockets. This is where fuel tank level sensors
come into the picture. So, lets rev our engines
and embark on this informational journey about
fuel tank level sensors!
What Are Fuel Level Sensors?
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Fuel sensors or fuel level indicators are
ingenious devices installed inside the fuel tank
to measure the accurate fuel level in real time.
The data is shared with telematics software such
as TrackoBit which massage the raw data and
present the users in a digestible format. These
sensors are further categorised into various
types depending on the technology they use to
gauge fuel levels. The following section will
shed light on them in detail. As far as the use
cases of fuel tank sensors are concerned, they
help fleet managers Measure fuel consumption
patterns Plan fuel refills and stops Maintain
the overall fleet efficiency Enhance vehicle and
consignment safety.
Applications of Fuel Tank Level Sensors Where
ever the requirement for diesel, petrol or any
sort of fuel is there, the application of fuel
level sensors exists. Some common domains where
fuel sensors are applicable Moveable units
Vehicles, Vessels, Earthmovers, etc. Stationary
units Generators, Machines, Fuel Pumps, etc.

• Types of Fuel Level Sensors
• Having only one option, is even an option? We get
  you!
• Cutting straight to the chase, the following are
  the common types of fuel level sensors used
  across industries.
• Capacitance Fuel Level Sensors
• Capacitive fuel indicators come with two
  electrodes that are immersed at the two ends of a
  fuel tank. The capacitance between the
  electrodes changes as the fuel level changes.
  This change in value is then converted into fuel
  level readings.
• Pros and Cons The accuracy of capacitance
  sensors are accurate. They are less susceptible
  to fuel sloshing and sedimentation. The best
  part- they are suitable for both liquid and gas
  fuels.
• They are popularly used in vehicles including
  cars, trucks, vessels, and machines as well.
• Ultrasonic Fuel Sensors
• As the term suggests, the sensors use ultrasonic
  sound waves to measure fuel levels. They emit
  sound waves towards the fuel surface, and the
  amount of time they take to reflect back
  determines the distance. Hence, the level of
  fuel is gauged.

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Pros and Cons Contactless measurement of fuel.
Its suitable for fuel tanks of different shapes
and sizes. However, the ultrasonic fuel tank
level sensor is a little expensive and potential
hindrance such as foam may compromise the
reading. These fuel sensors are commonly used in
automobiles, boats, and industrial appliances.
They come in handy when the instruments have
irregular fuel tanks and you require accurate
fuel level readings.

• Resistive or Float Fuel Indicators
• A float is connected to a potentiometer or a
  variable resistor that moves as the fuel level
  changes. Hence, the value of resistance also
  changes, resulting in a change in voltage. The
  dashboard displays the calibrated value in
  litres.
• Pros and Cons Its simple design makes it
  cost-effective and easily compatible with a wide
  range of fuel management systems. However, its
  values are not on point and susceptible to flaws
  due to fuel sloshing.
• The resistive fuel tank level sensors are most
  commonly used in cars, motorcycles and small
  boats.
• Magnetic Fuel Tank Sensors
• Also, known as Hall effect fuel sensors because
  they detect the changes in the magnetic field
  called the Hall effect. The sensor detects the
  change in fuel level when the change in magnetic
  fields is recorded.
• Pros and Cons Hall-based sensors offer accurate
  and non-contact fuel measurement even in
  asymmetric fuel tanks. Its higher cost and
  limited compatibility with most fuel types are
  its downsides.
• Applicable mainly in industrial fuel systems
  where compatibility with corrosive fuels is
  required.

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• Read more How To Reduce Fuel Consumption Using
  Fleet Management System?
• Benefits of Fuel Level Sensors in Optimising
  Fleet Operations
• One of the primary and most popular applications
  of fuel sensors is in automotive vehicles. In the
  fleet of commercial vehicles, where optimising
  each and every aspect of operations is a must to
  draw a profitable bottom line, petrol- level
  sensors prove to be a game changer.
• Lets elaborate on the benefits of fuel sensors!
• Improved Fuel Management
• Real-time, as well as historical data, enable
  automatic alerts such as fuel refill reminders,
  fuel leakage, pilferage or abnormal fuel
  drainage. Advanced fleet management software also
  provides a list of nearby fuel stations and
  current fuel prices in different states, allowing
  fleet managers to plan fuel refilling stoppages
  accordingly.
• Increased Vehicle Efficiency
• With real-time and accurate fuel level updates,
  drivers and managers can make informed decisions
  pertaining to fuel refilling, vehicle health,
  and trip planning. If certain vehicles are
  consuming more than usual fuel, it means either
  the vehicle needs servicing or the driver is not
  practising eco-driving. Spotting such anomalies
  and correcting them at the right time improves
  overall fleet efficiency.
• Enhanced Safety
• Abnormal fuel drainage may be the result of
  leakage, which is not safe for the vehicle and
  consignment can be detected by fuel level
  sensors. Unannounced route deviations breed fuel
  pilferage which can be detected with a win- win
  combination of route deviation alerts and fuel
  monitoring reports. This is where the heroism of
  fuel-level sensors comes into play.
• Cost Savings

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6. Lesser Stress on the Environment Fuel sensors
indirectly help in environmental sustainability.
Reduction in fuel usage means lesser emissions of
carbon footprints. Ignorance is bliss and
reality is heartbreaking! When carbon emissions
take the shape of numbers, then only do we
realise our wrongdoings.

• How Fuel Level Sensors Work
• To keep it short and precise, the fuel sensors
  work in four simple steps. These steps include
  installation, function based on their respective
  principles, the transmission of data, and then
  the final output.
• Lets discuss the entire procedure in detail.
• Sensor Placement
• Before the technology and the device work as
  expected, its important to check the
  compatibility of the fuel sensor with the
  software. After the device gets a nod from the IT
  team, the sensor is installed in the fuel tank.
• The exact placement of the fuel monitoring device
  may vary depending on the fuel system and
  vehicle/fuel tank design. The sensor is
  strategically placed to draw accurate readings.
• Sensor Operation
• After the sensor is mounted, it starts operating
  on its respective principles such as resistive,
  capacitive, ultrasonic or magnetic. The sensors
  detect the fuel level in their respective units.
• Signal Processing
• The information received by the sensor pertaining
  to fuel levels is then converted into an
  electrical or electronic signal. The signals get
  recorded either in voltage, resistance,
  capacitance or frequency. The recorded signal is
  then sent to the software via the cloud.

Fuel Tank Sensor Calibration
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Calibration of fuel sensors or tanks is important
to adjust the devices readings to accurately
measure and reflect the fuel levels on the
dashboard. Fuel calibration is important because
factors such as disparity in fuel density, sensor
drift, and installation variations can affect
the values. Therefore, to avoid inaccuracy of
data and wrong business decisions pertaining to
fuel management, calibration is crucial.
In measurement technology and meteorology,
calibration is the process of adjusting and
aligning the measurement of instruments(in this
case fuel tank sensors) to match a defined
reference or standard, ensuring accurate and
precise readings.
Fuel Level Calibration Procedure The calibration
process for most fuel monitoring systems is more
or less the same. In the commercial space, most
of the fleet techniques use the following
technique to calibrate fuel. Step 1 Measure and
pour the stipulated volume of fuel into the fuel
tank, referred to as a pass. Ideally, a pass is
1/10th or 1/20th of the tank volume. This
ensures enough entries on the calibration table.
If the total tank volume is 20 liters then each
pass of 1/10th will amount to 2 L. This means
there will be 10 readings on the calibration
table. You can use transfer pumps to measure the
exact volume of the pass.
Step 2 Record the reading received either in
voltage, resistance, frequency, etc.
corresponding to the pass value (measured in
liters or gallons) in the calibration
table. Step 3 Repeat the process as you keep
adding the passes and the fuel level sensor keeps
changing the value. Step 4 If the tank has an
irregular shape, adjust the pass volume by
dividing it by two as you reach the asymmetrical
area of the tank. Step 5 Define and feed these
values of the calibration table on the Fleet
management software you use and test the fuel
monitoring for data output.
Tips For Accurate Calibration Follow the
calibration specifications and instructions
provided by the manufacturer for the given
model. Calculate variance using mean, median or
mode to minimise measurement errors.
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Fuel Monitoring By TrackoBit A good sensor
becomes the best when it joins forces with
intelligent software. TrackoBits advanced fuel
monitoring solutions bring out the best fuel
monitoring solutions. TrackoBit allows remote
fuel monitoring in a few clicks. Once the sensor
is integrated with the software and the
calibration is done, you are good to go.
Read more Improved Fuel Efficiency and Enhanced
Fleet Safety Go Hand-in-hand with TrackoBit.

• Offerings of Our Fuel Monitoring System
• Real-time Fuel Level Update
• Our fuel monitoring system delivers real-time
  fuel level updates on each vehicle in the fleet.
  The real-time visibility into such data helps
  fleet managers make instant business decisions
  confidently.
• In-depth Fuel Report
• Analyse fuel consumption patterns with the help
  of insightful reports on fuel average, refill,
  and drainage. Fuel charts display absolute
  mileage with respect to speed, ignition on/off,
  distance travelled, etc. You get trip-wise,
  vehicle-wise, and driver-wise fuel reports for
  better analysis.
• Instant Notifications
• Get live notifications and alerts every time fuel
  levels drop/rise instantly or abnormal fuel
  consumption patterns are detected. The software
  shares notifications/alerts via SMSs, WhatsApp
  messages, push notifications or emails.

Know More About TrackoBits Fuel Monitoring System
Frequently Asked Questions About Fuel Level
Sensors Q.1. How do I reset my fuel level
sensor? Ans Resetting the fuel gauge in the
vehicle is completely different from resetting
the fuel tank level sensor in a commercial
fleet. If we talk about resetting the fuel tank
sensor, it simply means recalibrating the sensor
readings. In case there is an error code from
the softwares point of view then fix it before
recalibrating.
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• Where is the fuel level sensor located?
• Ans The fuel tank level sensor is located inside
  the fuel tank as it has to measure the fuel level
  at all times. However, the exact position of the
  installation may vary from the type of vehicle to
  the type of sensor used.
• Can I get fuel level readings on the software
  dashboard with an external fuel level sensor
  installed in the vehicle?
• Ans Yes, with the help of OBD CANBus data, it is
  possible to derive the fuel level readings from
  the central unit of the vehicle.

Diksha Bhandari Currently creating SaaSy content
strategies for TrackoBit and TrackoField, this
content professional has dedicated a decade of
her life to enriching her portfolio and continues
to do so. In addition to playing with words and
spilling SaaS, she has a passion for traveling
to the mountains and sipping on adrak wali chai.
View all posts
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