Digital Output - Fuel Level Sensors

Digital Fuel Level 

When you enter the term above in Google you get a variety of responses most of them showing a display indicating fuel as a digit value on a screen.

What this is a numerical  manipulation of the the analog signal that most fuel level senders provide as an output:

Simple electronic analog values are the tradition for fuel level measurment.

• Resistance
• Capacitance
• In the case of Reed Switches  - Current or No Current.

But what we have is just another way of showing what analog sensors are providing digital is display only.

Digital output at the Sender is Unique - there are several aftermarket Capacitive Sensors in the Marine industry or Telematics that use a conditioned digital output.  There are conversion processes for these senders - temperature compensation signal conditioning maybe a de- bounce (smoothing) function.

Capacitive senders take an analog signal give it a binary component and communicate the signal.

What if the native language of the sensor were digital in that each fuel level was represented by a binary stream - natively   No conversion - no compensation - and if non contact

 No issues with Fuel quality or Fuel type  - NONE .

 In fact no compatibility issues with the measured liquid in question whatsoever

When Fuel is Important or Critical to Operation
Fuel level is important but what if knowing how much remained meant the difference between an inconvenience or something more significant.

The manner in which we handle the digital output signal is proven in aviation applications -

Signal integrity is paramount - in an environment where static charge and exposure to radiated fields would bring most fuel level systems to their knees.  If you couple the requirements for vibration shock and the extremes in temperature - it is surprising that any fuel level sender works at all in aviation.

So why Digital 

• The level output is provided continually -
• The Fuel Level is reported over and over again to the gauge or display
• The signal does not suffer from signal loss or interference
• Either the complete signal is transmitted or nothing at all 
• Not effected by voltage variation
• Many more data points to map the fuel tank
• 3,800 distinct points for 80 degrees of travel possible 
• No Temperature Effects 
• No compensation
• The device will output fluid temperature if required
• Failure is hard and the results predictable
• False signaling of tank volume due to wear is virtually eliminated.

Imagine a level sender that thrives in the critical  aviation environment and think what it could do for your application.

Fuel Level Sensors for Collector Vehicles

Aviation Float Fuel Sender - Historical Perspective

Dawn of Aircraft Instrumentation

The initial non-electrical float system was used on various aircraft, the most famous being the Piper J-3 "Cub." which used a cork with a wire imbedded in it that extended into the view of the pilot. Lots of wire showing, lots of gas; no wire showing, no gas.  Equally glass sight gauges are used in high wing aircraft and high wing fuel can to flow to the engine by means of gravity.

Electrical Aircraft Instrumentation Comes of Age

With the addition of electrical systems in aircraft the float was connected to the arm of a variable resistor whose electrical leads are brought through the wall of the tank and connected to the fuel quantity gauge and to the ship's electrical bus. 

Thus, the change in resistance as the float follows the level of the fuel.  This electrical value causes the needle on the fuel quantity gauge to deflect indicating the quantity of fuel in the tank.  Simple and direct.

For odd shaped tanks, particularly a flat tank in a wing with dihedral, multiple resistance floats are connected in series to correctly categorize this onger sloped tank.

This is the fuel gauging system on most, if not all, automobiles, the majority of piston engine aircraft, and some turbine aircraft. This system has been given very poor reviews over the years, some of which is deserved, but a large portion of the criticism is not.

If the resistance float is poorly designed and constructed, if the gauge is poorly designed and constructed, if the gauge is poorly marked, if the damping of the complete system is not suitable for aircraft or it's particular use,  or if the system is poorly installed and calibrated,  criticism for poor operation is rightly deserved. 

Digital Display and Interface  

In the instance of fuel level - Nothing really 

Well in the case of Commercial Aircraft the capacitance value was converted to ARINC 429 protocol and transmitted to the cockpit.

Until Now 

The First Digital Output General Aviation Fuel Level Sender 

  

Fuel Level Senders - Automotive

Fuel level sending has been the providence of electrical resistance since somewhere in the 1930's when electrification of the automobile hit full stride.  The Ford Model A used a very clever sight gauge so that you actually saw a liquid representation of fuel level - neat design but expensive.

http://www.facebook.com/Fuellevel

Resistance Level worked very well and was easy to understand  -  X Ohms Full - Y Ohms Empty

Simple

And then suddenly somebody decided to add alcohol -  to fuel -

Methanol and ethanol contain soluble and insoluble contaminants.[5] Halide ions, which are soluble contaminants, such as chloride ions, have a large effect on the corrosively of alcohol fuels. Halide ions increase corrosion in two ways: they chemically attack passivating oxide films on several metals causing pitting corrosion, and they increase the conductivity of the fuel. Increased electrical conductivity promotes electrical, galvanic and ordinary corrosion in the fuel system. Soluble contaminants such as aluminum hydroxide, itself a product of corrosion by halide ions, clogs the fuel system over time. To prevent corrosion the fuel system must be made of suitable materials, electrical wires must be properly insulated and the fuel level sensor must be of pulse and hold type (or similar). In addition, high quality alcohol should have a low concentration of contaminants and have a suitable corrosion inhibitor added.

So if you turn to any car chat blog (ANY CAR CHAT BLOG)  -

Failed fuel level sensors are driving OBD II cars to the shoulder.

So we need to find a replacement  Smiths (Stewart Warner, VDO, Veglia, Et al) in a Pulse and Hold fuel senders - Not compatible 

We are producing  a patented new non-contact fuel level sensor.

We are applying the sensor presently  to aviation (aircraft, rotorcraft) - In aviation we don't have alcohol,  but we can't put wires in the tank - something about electricity and fuel

Aviation  requires - what cars - all cars using Alcohol mixed fuel need - A non contact fuel level sensor

It is also helpful in this environment 

Fuel Level Sensor Under Test

We use a new concept in our sender called Magnetoresistance - certain materials change resistance in the presence of a rotating magnetic field and they can do this from as far as 3/8" away actually from the dry side of the tank.

Most of us see this everyday in the compass on our smartphone

There is no pivot or contact resistance,  so the float can be smaller and the range can be larger (fuller fulls and emptier empties)

Neat thing is that the  output of this sensor  can mimic a resistive sensor

Hey if you find this interesting let us know

scott.philiben@ciescorp.com

The answer to a more accurate reliable Fuel Level Sender - May be right in front of you.

Service Bulletin

In a recent software update - two items were added

These selections were not part of the previous software options list.  

Let us know if you would like more information.


More Information

Cascade Business News - Again

CiES Advances Patented Fuel Sensor Technology to New Markets

Roland White

Redmond company develops new Digital Fuel Level units for use in aviation, marine, propane and agriculture applications.

CiES Inc, was founded in 2010 with the idea to manufacture a highly accurate fuel sensor technology targeted for the aviation industry. Company founders Scott Philiben and Richard Kirkness seized an opportunity when they purchased the patent for AMR fuel level sending, (Anisotropic Magneto Resistive technology.)

Since their startup they have perfected the CiES Digital Fuel Level Sender unit, established production and are selling units worldwide. The patented unit is FAA Certified and installed in current production aircraft. It is the fuel sensor equipment of choice for Cirrus Aircraft and an approved to retrofit many of their previous models.  

Philiben says, “Fuel accuracy is in the top five safety issues in aviation but accuracy is important in other forms of transportation. The unit has achieved a nearly 100 percent supplier rating from Cirrus Aircraft. With almost 4,000 units being used worldwide.  The fact that we haven’t had any warranty issues due to a product problem in aviation is phenomenal almost unheard of and a testament to our technology.”

CiES fuel sensor technology is being adapted to new markets with success in transportation, agriculture, marine and recreational applications. Philiben explains, “Where we saw the value of the patent was that people have the same fuel reading problems in aviation with boats, heavy equipment, recreational vehicles and other forms of transportation.”  

“Almost everyone has a story about running out of gas at some point in their life,” explains Philiben. "Most manuals for aircraft, marine and recreational vehicles tell you to don’t trust your fuel gage.  We’re restoring the trust in that gauge with the right technology.   The sender is so accurate that you can actually updates your range calculation based on actual fuel on board.   So with this concept we have developed some interesting technology that we are applying towards these new market niches.”

CiES has experienced additional success with propane fuel sensors providing  extremely good results.  Philiben says, “The first aircraft we did a retrofit on, it turned out that the old fuel sensor was the same type as used in the propane tank industry, so we evaluated this sender and found it totally unsuitable for the aviation job and questionable for the original market application.  We created a better device based on the AMR technology that produced the same high accuracy in propane level as the CiES units used for aviation.”

Once they had the propane fuel sensor developed they had an opportunity to test the units in a larger scale. Philiben says, “Our first foray into propane fuel sensors came from an inquiry from Italy, where there is the highest percentage of consumer propane vehicles that run on dual fuel technology, burning both gas and propane. In developing this product we utilized a wi fi device that included an iPhone app to read for the remaining fuel levels.” Although the propane sensor experiment in Italy didn’t produce any contracts they later reached out to two large propane suppliers for further testing with Roush Clean Tech and Clean Fuel USA.

As it turned out a fleet of buses powered by Roush Clean Tech propane tanks are running here in Central Oregon by the Bend La Pine School District. We will outfit several buses with CiES propane fuel sensors in their buses for a pilot evaluation. Philiben says, “So now the manager of the fleet is thrilled to have the technology to determine which buses need refueling and to calculate the savings they produce by using propane rather than diesel.” Gary Fiebick, operations and routing manager for special education transportation for Bend. says “The Bend-La Pine School District began acquiring propane buses about three years ago and now uses them on 18 of 21 special education routes.”

Philiben is excited when he says, “We are expanding this concept into other markets.  For anyone who has an RV They will tell you it’s no fun to crawl underneath your vehicle just to see how much propane is in the tank.  I have my RV equipped with the device and I can check the propane level with an iPhone App.

In addition to the aviation industry the CiES Fuel Level Sensor is ideally suited for  trucks, heavy equipment, lawn mowers, lift trucks and automobiles. This technology can also be adapted to include the home consumer market where the sensor can be used with home BBQ tanks letting you know by email that you are running out.

With 2013 nearly on the books Philiben looks back and says, "We grew by 100 percent from the year 2012.” Looking ahead into 2014 CiES is striving for another 100 percent increase in business.  

Philiben explains, “We already have the largest aircraft builder using the CiES fuel Sensors on their OEM’s and we are getting the second largest builder sometime soon.” Philiben elaborated on the possibilities for the propane market where CiES is considering courting investment partners. 

Philiben concludes, “Propane? We have to make that a go in the after markets we’re approved in... We will push really hard for those additional markets, automobile, marine, RV, commercial and Industry users that require accurate fuel sensor technology. " If a propane vehicle conversion company commits to CiES as OEM equipment vehicles, we will be slammed and most likely double in size.”

Local Recognition - Cascade Business News

Cascade Business News 

Pamela Hulse Andrews

If the recent Made in Redmond Tour organized by Redmond Economic Development Inc., (REDI) is any indication, Redmond is on a fresh path to promoting its economic opportunities. In addition, its new City Manager Keith Witcosky and interim Airport Manager Bob Noble bring innovative perspectives to expanding Redmond’s economic potential.

Last month REDI invited community members, business owners, educators and government leaders to tour several unique businesses. Four companies were showcased that manufacture unique products in Redmond including Key Technology, CIES, McConnell Labs/Light Elegance and Central Oregon Truck Co.

Jon Stark, manager of REDI, says the companies selected are successful examples of the progress that has been made in economic development. REDI and Economic Development of Central Oregon (EDCO) have collaborated extensively with city, county and state leaders in cultivating a fertile climate for business to be successful in Central Oregon.

While acknowledging the success of current Redmond companies, REDI is looking at soon-to-be newly zoned 465 acres of industrial land, some private and some airport owned, that will include parcels from 30-50 acres for attracting larger scale industrial and manufacturing companies.

Redmond may not be as sexy as Bend with its appealing high end retail and boutique shopping, numerous restaurants and cultural events, but companies wanting to move to our region will find Redmond a very favorable place for reasonably priced site and development costs, a competent workforce, affordable labor costs for their business and transportation access including a world class airport.

Redmond gets high marks, too, for paving the way for development, resolving zoning issues and mitigating important site or expansion matters.

.......

Another Redmond company,  CiES Inc provides reliable fuel sensors for aviation. CEO Scott Philiben says, “CiES employs mechanical and electrical engineers and high quality skilled workers. We make about 3,000 devices a year and have recently added six jobs to the Redmond economy. We will grow at 50 percent per year for the next several years.”

CIES has improved on a patented fuel sensor technology and produces systems that are designed to provide exceptional fuel level accuracy in the harshest conditions imaginable. The company is successful in the world aviation market and is leading the technology for additional liquid fuel markets in the U.S. and Europe.

These companies, along with the entire Central Oregon region, depend on the Redmond Airport, some for shipping products, all for business travel. With a steady increase over the years in passenger flights and upgrades and expansion of facilities the Redmond Airport has positioned itself to be the central hub for transportation in Central Oregon.

Redmond’s new city manager lured Nobel, an experienced airport manager, to help him guide the direction of this significant ecnomic asset. Nobel has more than 18 years of experience in numerous public aviation leadership roles across Oregon.

Given the importance of the airport to the region’s growing economy and transportation needs, Nobel has been charged with working on long term airport goals including assessing the current airport environment, identifying critical issues and developing the processes for implementing changes.

Witcosky is looking ahead and says he wants the Redmond Airport to become known as the best airport of its size in the nation. “That means it will be the preferred choice for commercial air carriers and general aviation clients based on the best services, infrastructure and facilities of any airport of similar size in the country. Clients will recognize this value by investing through leases and other contracts which allow the airport to be a self-sustaining and continually improving community asset.”

Redmond has a vision and summarized by its new city manager: “Our vision is that aviation, aerospace and other traded sector industries continue to invest and cluster around the airport. Partners such as Redmond Economic Development Inc. (REDI) and Economic Development for Central Oregon are working with us to create jobs and attract private sector investment.”