Fleet Fuel Management System

System Overview

Fuel is typically 30-40% of fleet operating costs. This system helps reduce costs through monitoring and optimization.

Fuel Sensors

Type	Accuracy	Cost	Installation
Ultrasonic	±1%	$$	External mount
Capacitive	±0.5%	$$$	Drill required
Float	±3%	$	Tank access needed
OBD-II	±5%	$	Plug & play

Hardware Setup

• ESP32: Main controller
• Ultrasonic Sensor (JSN-SR04T): Waterproof fuel level
• GPS Module: Location tracking
• 4G/NB-IoT: Cellular connectivity
• Accelerometer: Crash/tilt detection

ESP32 Firmware

#include <TinyGPS++.h>

float readFuelLevel() {
  // Send ultrasonic pulse
  digitalWrite(TRIG, HIGH);
  delayMicroseconds(10);
  digitalWrite(TRIG, LOW);
  
  long duration = pulseIn(ECHO, HIGH);
  float distance = duration * 0.034 / 2;
  
  // Convert to fuel percentage
  float fuelPercent = map(distance, 5, 50, 100, 0);
  return constrain(fuelPercent, 0, 100);
}

void detectTheft() {
  static float lastFuel = 100;
  float currentFuel = readFuelLevel();
  
  // Sudden drop = potential theft
  if (lastFuel - currentFuel > 10 && !engineRunning) {
    sendAlert("FUEL_THEFT", currentFuel);
  }
  lastFuel = currentFuel;
}

Theft Detection

Common theft patterns the system detects:

• Sudden Drop: >10% when engine off
• After Hours: Fueling outside schedule
• Location Mismatch: No gas station nearby
• Frequency: Too many refuels

Analytics Dashboard

// Fuel consumption query (InfluxDB)
SELECT mean("fuel_level") FROM "fleet_fuel"
WHERE time > now() - 7d
GROUP BY time(1h), "vehicle_id"

// Calculate MPG
SELECT (distance / fuel_consumed) as mpg
FROM "trip_data"
GROUP BY "vehicle_id"