Gill R&D Liquid Level Sensor for next generation energy storage

May 14, 2014

A liquid level sensor for use with de-ionised water in a fuel cell system was required by a leading power technology company specialising in the development of Proton Exchange Membrane fuel cells. The application was for an automotive facing project so long term reliability and low cost of ownership was essential.

The Challenge

The core capacitive technology offered by Gill R&D provided the key parameters required by the customer, however the requirement for a minimal dead zone at the end of the sensor probe required an adaptation of the standard product offered.

The Result

The high levels of vibration, temperature fluctuation and shock loads experienced within the application reinforced the suitability of the proven, solid state capacitive technology offered by Gill R&D.

A sensor was designed utilising the technology and electronics of the existing liquid level sensor solutions. We designed the sensor with a reduced component count and simplified assembly.

The length of the sensor probe was designed to optimise the customers' application rather than the standard, off-the-shelf product currently used, and the manufacture of the sensor in stainless steel and FEP also meant that materials compatibility issues encountered with the previously specified sensor were eliminated.

Project results and benefits

• Solid State reliability
• De-ionised water materials compatibility
• Integrated electronics
• Stainless Steel construction
• Customised length
• High temperature capability
• Simplified assembly increasing reliability

Phases of working with the customer

• Understanding of application and product requirements
• Customised design generated to optimise sensor in application
• Design proposal submitted for customer approval and validation
• Manufacture of sensor for long-term testing and evaluation
• Delivered and calibrated to customer requirements

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