High temperature capacitive liquid level sensor

May 14, 2014

gill-rd-application-story-ht-remote.jpgA leading Motorsport manufacturer has identified a requirement for a high temperature oil level sensor to meet the increased temperature levels within modern racing engines and gearboxes.

These high temperature requirements are difficult to achieve using traditional liquid level sensors which are typically rated to a maximum of 125°C.

The Challenge

With sensing temperatures approaching 150°C, a sensor design was required that would meet the high temperature specification of the customer, whilst building on existing liquid level sensor technology in order to maintain high accuracy. A solution was also required within extremely short timescales due to the unprecedented levels of demand for the new engines.

The Results

Gill R&D developed a new high temperature Liquid Level Sensor in rapid timescales using state of the art product development methodologies. Virtual computer design tools were utilised to optimize the design to meet the high levels of temperature, vibration and weight targets.

Rapid Prototypes were also developed in-house for performance and application testing to ensure the design meets the rigorous quality standards for the customers new race engines.

The electronic circuitry has been separated into a high temperature sensor circuit located at the sensor head and a separate remote mounted electronics module located at a bulkhead mounting. Existing Gill processing electronics solutions are used to provide a 0-5V analogue output.

The high temperature liquid level sensors developed by Gill are now supplied by Gill Sensors for the majority motorsport liquid level applications.

Project results and benefits

  • Delivered a robust and reliable remote sensor solution for use in high temperature applications (operating temperature range for probe -40°C to +150°C).
  • Provided full in-house support and testing facilities to ensure a fit for purpose product
  • Factory calibrated to ensure high accuracy over specified temperature ranges
  • Used Gill capacitive solid-state technology to sense the level of liquid to ensure excellent long-term reliability and performance confidence in the harsh motorsport application
  • Provided technical aftercare and support.

Phases of working with the customer

  • Customer brief and requirements capture
  • Concept Definition, analysis & optimisation
  • Detailed design of the new high temperature sensor, PCB and software
  • Prototype manufacture
  • Design verification and application testing
  • Production pilot build and product launch



Do you have a new development requirement?

We have extensive experience taking projects through all phases of development, in rapid timeframes.


Tel: +44 (0)1590 613400








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