BenDupre wrote:I don't know why engineers haven't solved this problem in the first 100 years of making cars.
It's solvable, it's just more expensive.
The three components of a fuel measuring system are a fuel tank, a readout gauge, and a transducer...the unit that takes the the fuel level in the tank and converts it into an electrical signal the readout gauge can use. Typically, the transducer is a small float on the end of an arm connected to a potentiometer; a device like a volume control. As the gas level changes, the float rises and falls, causing the output of the potentiometer to change.
As it does this...it's moving in an arc. Since it moves in an arc, the output of the transducer is proportionate to the angle of the arm. But the fuel level..what you're trying to read... is the cosine of the angle, not the angle itself. The output of the transducer is indeed linear, but it's linear as to the *angle*...which isn't the same as a linear output to the fuel level.
Three ways the designers can handle this. First, they adjust the arm length and the total arc of movement to measure a fairly short section of arc...you pick the right section of arc, and the angle output is much more proportionate to the cosine. The trouble here is that you're now measuring over a fairly short range, which means any errors produce wide variations. The transducer as to have higher resolution, which makes it more expensive to manufacture.
Second, they can play with the circuitry so that the arm outputs the cosine, or the gauge itself does the conversion. But it's MUCH cheaper to make things linear. If everything is linear, you can use the same basic transducer on many fuel-tank shapes and use the same basic gauge movement on many cars.
Third, they can bite the bullet and calibrate the fuel gauge itself. You'd still have "Full" at the top and "Empty" at the bottom, but the intermediate marks would be offset up or down, depending on the calibrated output of the fuel-sensing system. The "1/2" mark, for instance, might be where you might normally expect the "3/4" mark, for example, with the rest of the markings similarly offset. I had a '70s VW Beetle and a "Thing" that had such a disproportionate gauge.
The other factor that kicks in is fuel tank shape. Fuel tanks are often a bit narrower at the bottom than they are at the top. This will throw off the gauges as well; make it look like the car is burning fuel faster as the tank gets near empty. In this case, only the third option above would help.
Yes, these days, car manufacturers could computerize the fuel gauge and just put in a "look up" calibration table to display a very accurate fuel level. But it's still much cheaper to use the same type of fuel transducer and fuel gauge that the '47 DeSoto had.
As a final note, I'll reference the Federal Aviation Administration's certification standard for small aircraft, including small commuter-like planes. 14 CFR 23.1337(1) reads, "Each fuel category indicator must be calibrated to read 'zero' during level flight when the quantity of fuel remaining in the tank is equal to the unusable fuel supply."
In other words, even most *aircraft* aren't required to have accurate fuel gauges! They're only required to read accurately when the tank is empty....the "1/2", "3/4", "Full" markings, etc., don't have to be accurate.
So don't feel so bad if your car's gauge is off. :-)
Ron