Design Evolution of the Fuel Sender Requiring No Electrical Calibration

Design and manufacture of fuel senders include adjustments to establish accuracy of measurement of the amount of fuel in the tank and that show on the gage in the passenger compartment. The essential techniques are:

1. 1)
   Electronic calibration; design and manufacturing of the resistor and matching parts to assure the response resistance matches both mechanical and electronic gage characteristics.
2. 2)
   Mechanical calibration; design and manufacturing of the float arm and related geometric and trigonometric points, distances and angles that assure the position of the float at all fuel levels respective to fuel gage indication.

Vehicle manufacturing firms have used angular sweep liquid level sensors for measuring fuels for several decades. These designs incorporate the capability of linearizing (via angle relationships) height and volumetric fuel tank characteristics very accurately. While vertical linear type fuel sensors can provide better gage resolution, unless the design contains a form of linear resistance, the increased cost outweighs the improved resolution realized. Angular sweep resistor liquid level sensors are accurate, reliable, durable and inexpensive.