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Tank Level Sensor



What were this wonderful simple times when in the VW Beetle float in the tank and fuel gauge (pictured below) were so close together that they could be connected by a small Bowden cable. The fuel gauge then showed besides the fuel level even gratis by motion, curves, acceleration and braking, later it was then damped stronger.


That was already the luxury version, because the Beetle has yet witnessed the times of reserve cock. Began the car to jerk due to lack of fuel, you had to actuate it and knew exactly how far you could still drive without refueling. Of course, today it would no longer possible with the tank rear. Should even be present a reserve light, an electrical contact is necessary. But surprisingly, that one remained largely at a mechanical-electrical solution in the automotive sector.

But there are solutions that are less susceptible to interference. Should, for example, only one switching operation be performed, it is sufficient to direct the current to the base of a transistor via a suitable resistor and two pins, the immerse from a certain liquid level and trigger a switching operation. Thats how works e.g. the warning against excessive water level in diesel fuel filter. An additional circuitry prevents permanent on/off. However, such a solution requires relatively uniform resistance of the liquid.

With no moving parts, and regardless of the soiling of the medium to be measured is the measurement with ultrasound, which e.g. there are also waste holding tanks of boats. It should cope even deposits at the sensors. In contrast, of course, fuel is a much cleaner substance. For the come into consideration still a magnetically inductive and capacitive solution (next video).


A potentiometer sensor is obviously the most cost effective solution. It is also easy for the workshop to record e.g. metrologically (video below). A lot of electric motors no longer have carbon brushes, but breaks down the associated electronics, the is more expensive than the carbon brushes earlier. And all other solutions simply need more electronics. Nevertheless, these solutions are the future, if there are tanks still so long.


The very long resistance path (blue) is praised and connected therewith the large measuring stroke. This also applies to the voltage swing that can reach almost the on-board voltage. The resistance must not behave proportional to the degree of deflection, so it can better satisfy today's complicate design of fuel tanks. This is, for example, influenceable by the width of the measuring base. The second contact track usually has different resistance values.

Pictured is an angle potentiometer. But it is also possible with vertical up and down moving float. At the conductor tracks would make sense an effective seal against fuel. However, this makes difficult the individual exchange or repair. Mostly, the exchange of the not very cheap, complete module is due.

On the function of the protruding float mechanics and especially the correct alignment is to pay particular attention during installation. Please mark the hoses for supply and return. If pump delivery pressure and delivery amount are reasonably correct, you can exchange the pumps of petrol car and diesel car. However, the strainer is slightly more coarse-meshed for diesel cars. 10/15








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