Hardware-Level Fuel Monitoring for Fleet and Industrial Assets

## Overview Fuel is typically the largest operating cost for any fleet — and also one of the most vulnerable to waste, inefficiency, and theft. OBD-based fuel estimates are useful for light vehicles, but for HGVs, plant, generators, and any asset with a large diesel tank, direct tank measurement using a dedicated fuel sensor is the only way to get accurate consumption data. Our fuel sensor hardware integrates directly with the telematics platform, so every fill event, consumption calculation, and theft alert appears in the same dashboard as GPS tracking, driver behaviour, and maintenance data. ## Capacitive vs Ultrasonic: Which to Choose **Capacitive sensors** are the most accurate option and the industry standard for high-value fuel monitoring. They are installed by inserting the probe through the tank top (a small hole is cut if one does not already exist) and connecting to the telematics device via analog or digital signal. Installation requires access to the top of the tank and is typically performed at the same time as the GPS tracker installation. **Ultrasonic sensors** are the right choice when the tank cannot be accessed from the top, or when a non-invasive installation is required (leased vehicles, warranty-sensitive tanks). They attach to the external base of the tank using adhesive and measure fuel level through the tank wall using ultrasonic pulses. Accuracy is slightly lower than capacitive sensors but sufficient for most fuel management applications. ## Fuel Theft Detection in Practice Fuel theft from commercial vehicle tanks is more common than most fleet managers realise — and it's not always external. Our platform monitors the rate of fuel level change and triggers an alert when a drop is detected that is inconsistent with normal driving consumption. Alerts include GPS coordinates, time, and a link to the fuel level graph at the time of the event, giving fleet managers the evidence they need to investigate and act. ## Reconciliation With Fuel Card Data When combined with our fuel card integration, the platform automatically reconciles physical fuel sensor readings against fuel card transaction records. Discrepancies — where the card shows a fill that doesn't appear in the tank data, or the tank shows a fill with no card transaction — are flagged automatically for investigation.