Gill R&D capacitive Oil Level Sensor for underground mining equipment

May 19, 2015

Gill Intrinsically Safe Level SensorA global manufacturer of heavy plant machinery required an extremely robust oil level sensor to measure the level of lubricant in the gearbox of underground mining plant equipment.

The Challenge

One of the key customer requirements was the need for a sensor which could simultaneously report the oil temperature. The device needed to be ATEX certified in order to suit the dusty and explosive environments it was to be deployed.

The Result

The solution was based around the proven technology and robustness of Gill's standard oil level sensors. However, the sensor had to be re-engineered to integrate with the mating interface, made Intrinsically Safe (IS), and incorporate the PT thermistor into the sensor probe to provide the oil temperature measurement.

Additionally, new electronics hardware and software were developed in-house to accommodate the temperature measurement inputs and to provide a 4-20mA output.

Gill Intrinsically Safe Level SensorProject results and benefits

  • Developed stainless steel measurement devices, sourced to comply with IS requirements to ensure maximum resilience to formidable operating environments
  • Co-ordinated the IS certification process, sourcing the appropriate testing agency and securing certification for additional international markets, as requested by the customer.
  • Full project management services provided to ensure a tight production schedule
  • Successfully installed oil level sensors into 500 gearboxes of mining plant equipment

Phases of working with the customer

  • Re-engineer sensor to customers specifications
  • Develop new electronics hardware and software
  • Source Intrinsically safe components
  • Submit design to customer for approval
  • Produce prototypes for evaluation and approval
  • On receipt of approval, submit sensor for IS certification
  • Produce all supporting documentation for IS certification
  • Manufacture and deliver sensors on time and on budget
  • Support further IS certification for additional countries


Did you know...

The Gill Instruments WindObserver Intrinsically Safe ultrasonic anemometer is certified by the International Electrotechnical Commission (IEC) for use in explosive atmospheres (Ex). Find out more at



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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