Achieving maximum accuracy in fuel level measurements for agricultural machinery is supported by Galileosky trackers

Background

The "Oktyabrskaya" agricultural firm has been engaged in grain cultivation for over 20 years. Its fleet consists of approximately 40 units of machinery, including combines, tractors, carriers, sprayers, and passenger vehicles.

One of the issues the agricultural firm addressed with TN-Group was a high percentage of discrepancies in refueling data between gas station records and their own measurements.

After an audit, it was found that the high error rate was due to drivers and operators filling tanks to the brim. When refueling vehicles, the accuracy of the fuel level sensor depends on the type of machinery and the shape of the fuel neck, which can lead to errors of up to 6-10%.

Moreover, the sensor cannot track changes in fuel levels at the neck for obvious reasons—it is designed only for tank measurement. Consequently, monitoring this volume of fuel becomes impossible, increasing error rates and potentially allowing for unnoticed fuel siphoning.

Project objectives

• Improve the accuracy of fuel level data.

• Reduce discrepancies between gas station readings and internal measurements.

Solution

TN-Group addressed this challenge by implementing a fuel tank filling indication system that includes equipment, algorithm development in Easy Logic, and refueling regulations for drivers.

The system operates on the principle that tanks should be filled not to 100% but to a recommended level of 90-93%. In this range, the fuel level sensor operates with maximum accuracy, achieving an error margin of no more than 3%. This ensures no unaccounted fuel volume, providing clients with an accurate picture of consumption.

Implementation Steps:

1. A light indicator was installed on the machinery to signal when the desired fuel volume is reached. Drivers must stop refueling upon seeing this indicator.

2. The monitoring system adjusts based on calibration tables and tank volume to display current tank fill levels as a percentage. This helps determine how many liters are needed to achieve optimal control (90-93% fill).

3. A major challenge was training drivers to fill tanks only to the recommended level. Initially, drivers claimed they did not see when the light indicator turned on; thus, TN-Group added an audible signal for greater effectiveness.

4. Additionally, operational guidelines were developed for monitoring equipment during fuel dispensing from both gas stations and mobile refuelers.

Result

1. Reduced fuel discrepancy errors by more than five times: from 6% to 1%.

2. Increased data accuracy.

3. Improved accounting: significant discrepancies previously complicated data reception from monitoring systems into accounting systems.

4. Decreased time spent resolving incidents and reconciling refueling data.