1) Eddy-Current sensor (Position type Potentiometer):

Working Principle: - When an electrically conductive flat or curve disk

approaches a coil to which high-frequency alternating current has been
applied, it has an effect upon the coil’s equivalent resistance and its
inductance. This is the result of the eddy currents generated in the disk
due to the increasing magnetic coupling. The disk’s position represents
the measured travel.
The generally high operating frequency (MHz range, a low-frequency
feed would take up too much current because of the low coil
inductance) requires a direct assignment of the electronics to the sensor
or a shielded supply lead, which is generally not supportable. In order to
convert the measuring effect into an electrical output voltage, either the
damping effect (Equivalent resistance) or field-displacement
(inductance) principles can be applied. In the first (damping effect) case,
a variable-amplitude oscillator can be used, and in the second a variable-
frequency supplied inductive voltage divider (differential configuration).

1. Spoiler
2. Eddy currents
3.Air-core inductor
4. Variable-damping
oscillator
5. Demodulator
s - Measured travel
A(s) Oscillator voltage
UA(s) Output voltage

Fig. 1 HF damping or eddy-current principle

There are many ways to adapt the eddy-current principle to the

measuring assignment. It is suited both the determination of large travel
distances or angle (there has already been a practically production-ready
development, for the throttle valve and accelerator pedal, for instance)
and also a very small variable (E.g. torque sensor). Because of self-
compensating properties, this principle generally only shows a very small
temperature sensitivity over a wide temperature range. As eddy-current
sensor can also, in principle, be manufactured micromechanically, their
future use cannot be completely written off given their very
advantageous properties. This sensor principle is, however, widely used
in manufacturing and quality measuring technology, for the precise
detection of the smallest displacement/distances or for the
measurement of layer thicknesses in the µm range.

2) Fuel-Level Sensor:
Working Principle:- The wiper potentiometer, usually made as an
angular-position sensor uses the correspondence between the length of
a wire or film resistor (Cermet or conductive plastic) and its resistance
value for measuring purposes. The fuel-level sensor is comprised of a
potentiometer with wiper arm (wiper string), printed conductors (twin-
contact), resistor board, and electrical connections. The complete sensor
unit is encapsulated and sealed against fuel. The float (fuel-resistant
nitrophyl) is attached to one end of the wiper lever, the other end of
which is fixed to the rotatable potentiometer shaft (and therefore also
to the wiper spring). Depending upon the particular version, the float
can be either fixed in position on the lever, or it can be free to rotate.
The layout of the resistor board and the shape of the float lever and
float are matched to the particular fuel-tank design.
The potentiometer’s wiper spring is fixed to the float lever by a pin.
Special wipers provide the contact between the wiper spring and the
potentiometer resistance tracks, and when the fuel level changes the
wiper move along these track and generate voltage ratio which is
proportional to the float’s angle of rotation. End stops limit the rotation
range of 100° foe maximum and minimum levels as well as preventing
noise. Operating voltage is 5-13 V. Measuring range of the fuel-level in
the fuel tank is 20-50 cm.
The job of the fuel-level sensor to register the level of the fuel in the
tank and send the appropriate signal to the ECU or to the display device
in the vehicle’s instrument panel. Together with the electric fuel pump
and the fuel filter, it is part of the in-tank unit. These are installed in the
fuel tank and provide for an efficient supply of clean fuel to the engine.
Advantages: -
1) Reasonable amount of accuracy.
2) Very reliable
3) Very extensive measuring effect
4)Low cost because of simple components.

1) Electrical connections
2) Wiper spring
3) Contact rivet
4) Resistor board
5) Bearing pin
6) Twin contact
7) Float lever
8) Float
9) Fuel-tank floor

Fig. 2 Fuel-level sensor

Disadvantages: -
1) Variation in contact resistance between wiper and measurement track
2) Testing is costly
3) Float affect by gravity and centrifugal forces.
4) Measuring errors due to abraded particles.