Case Study:


Aviation Case Study


It takes a lot of things to get a plane to fly and one of the most important is fuel. Too much and you are loosing efficiency due to extra weight, not enough and the outcome can be deadly. Whether a new plane design or retrofitting an old one, the importance of reliable fuel measurement can not be understated. In this case study we will discuss how both a super-sonic jet start-up and a pilot upgrading a 1970’s era L-39 Albatros jet decided on the Gill 4223 lightweight liquid level sensor.


When selecting a fuel sensor for use in aviation, designers are looking for a sensor that is:

  • Reliability under extreme conditions:
    • Fuel sensors must not only be reliable, but survive
      • Shock and vibration of landing/takeoff where 8 g’s is not uncommon
      • The physical force of fuel sloshing in the tank
      • Withstand years of submersion in aggressive Jet A fuel
      • Extreme high and low temperatures
    • Lightweight
    • Easy to integrate with available control systems
    • Easy to mechanically integrate / install

Tank mapping so that accurate measurements could be presented despite irregular tank shapes.


Gill’s 4223 lightweight liquid level sensor was born from Gill’s experience in building fuel and oil sensors for race cars. Optimized specifically for aviation and motorsports racing, the 4223 is not only lightweight, but also highly customizable and easy to integrate. Available in any length 100 – 750mm long and with five unique mounting flange options, the 4223 can easily be integrated into many designs. It’s 0-10V voltage output can be brought directly into an analog gauge or into a PLC or control system. Gill’s GS-Level software allows for users to easily perform tank mapping without performing any complicated math, simply add fuel in known amounts and GS-Level will do the rest. An optional fuel temperature output is also available along with a low-level alarm.


Gill fuel level sensors can be found not only in the applications discussed here, but also in UAV’s and single engine hobby planes throughout the world. In each application offering a unique balance of performance and reliability that only Gill’s proven track record can offer.