Power4Flight

EFI engine solutions for UAV powerplants

MENUMENU
  • Products
        • Engine Control
          • IntelliJect EFI
          • IntelliJect Developer’s Kit
          • IntelliGen Starter Generator Control System
        • Accessories
          • CE370 Series High Pressure Fuel Pump
          • Ignition Systems
          • CE214 Cylinder Head Temperature Sensor
          • Sensor, CHT, 330mm, JWPF Connector
          • CE215 Manifold Air Temperature Sensor
          • Fuel Injectors
          • Accumulator, CE, with Integrated Pressure Sensor
          • Accumulator, P4F, with Integrated Pressure Sensor
          • CBS-15 CAN Brushless Servo
          • Harness, CAN Pigtail, IntelliJect
          • Harness, Engine Interface, IntelliJect
          • Harness, Vehicle Interface, IntelliJect
          • Systec USB to CAN Converter
          • CAN Termination, 120 ohm, DB9
          • Triplex Metering Fuel Pump
          • Currawong H Series ESCs
  • Services
    • EFI Engine System Development
    • Engine Running Facilities
    • Customer Support
  • Downloads
    • Software
    • Technical Data & Whitepapers
    • Product Updates
  • Company
    • About Us
    • Latest News
    • Industry Links
  • Contact
B100i UAV Fuel Injected Engine

B100i Throttle Linkage Advisory – Inspection and Update

July 15, 2021

I.     Background

There are two types of throttle linkages currently installed on the various flavors of B100i engines deployed to customers. Recently one of our customers experienced a servo linkage failure related to the original (old-style) version of that linkage. This was the second documented failure of a B100i servo linkage arm.  Prior to the second failure Power4Flight and Cobra-Aero made a change to the linkage to address what we believed was non-optimal retaining clip engagement and retention. The clip in question holds the servo arm on the linkage ball. It should be noted that the original linkage configuration passed our 150-hour endurance test without failure.  

About a year ago a customer had a linkage failure and we put out an inspection directive and began tracking the issue. Ongoing inspections were showing some wear on the arms from the clips due to high vibration which we now believe was the cause of the first failure.  Subsequently, Power4Flight and Cobra decided to change the retaining clip configuration (see photos below) to minimize wear and improve overall retention and linkage robustness. This change was made and deployed on all new engine deliveries, prior to the second documented failure. The second failure that occurred was on an engine that should have been inspected and potentially updated if the inspection showed wear. The second failure is being attributed to wear from vibration between the hard steel retaining clip and the soft aluminum arm that we believe allowed the retaining clip to rotate and fall out – consistent with the first incident. The second failure happened even though we had implemented an inspection protocol and had a new replacement linkage available. Given we have experienced a second failure with the added inspections measures in place dictates that we need to remove all old-style linkages from service.

The new linkages, that were deployed after the first incident, hold the clip from the inside of the arm which limits the potential clip movement and to date seem to show less wear. We have had no failures with the new-style (current) arm. There is always room for improvement, so we are looking at further mitigation measures on the current arms that we plan to roll out once properly tested and validated. Until then we recommend that:

  1. Any engine with the old-style linkage be identified, inspected and grounded.
  2. All old-style arms be removed and replaced with the current version before being returned to flight.
  3. All engines with the current version of the linkage be inspected before returning to flight.

II.   Inspections

The first step for all B100i engine customers is to identify which linkage configuration you have installed on each engine. The diagram below shows the two versions side by side – the old-style is shown on the left and the current version is on the right. If you have an old-style linkage installed, we recommend that you contact Power4Flight so we can get you a replacement linkage assembly. We do not recommend flying the old-style linkages given we have seen a second failure.

If you have the current or second-generation arm on your throttle linkage assembly, we would like you to visually inspect prior to flying to make sure that there is no unusual wear or other potential issues. If anything looks unusual or different than expected, contact Power4Flight to discuss.

Feel free to call us for guidance if you are not clear on the identification/inspection procedure or have other concerns.

III.  Power4Flight/Cobra-Aero Follow on Actions

The plan going forward is to mitigate the potential for any further failures by removing the original or old-style linkages from service and replacing them with the current version, which we believe is an improvement, has been qualified, and not had any failures. We also plan to add further clip retention modifications and will roll out a third generation of the linkage once it is tested and fully qualified.

Once the suspect arms have been identified we will supply a kit and procedure for replacing them. The removal/replacement is simple and requires no adjustments, just the removal of the two ball link screws and old arm and the insertion of the replacement arm with ball links attached. 

IV. Customer Actions

Customers are advised to make the inspections outlined above on their entire fleet of B100i engines – installed on vehicles as well as any spares. Once completed you can send Power4Flight a SN list of engines that require the update, we will then send you the replacement servo arm assembly and the procedure to remove and reinstall them.

Recent Posts

Power4Flight focuses on software and electronics

July 19, 2022

Since its inception Power4Flight has focused on components for UAS engines - as well as complete engine solutions. As of July 1 2022 we will no longer … Continue Reading

Currawong Continues to set the Benchmark for ESC Motor Controllers

September 13, 2021

ESC Velocity Press ReleaseVelocity H Series ESC Part CD1101B / CD 1888 / CE1767 Datasheet Launching the latest innovations with the Velocity HS ESC, … Continue Reading

UAV Navigation Is Proud to Announce the Partnership with Power4Flight

June 14, 2021

UAV Navigation’s autopilot can now control the high-performance engines of the American manufacturer. Madrid, June 07, 2021 - As a … Continue Reading

Product Update Bulletins

March 17, 2021

Power4Flight has announced product update bulletins for the B50i Reed Mount, Fuel Filter 40 Micron and a 250W PMU Firmware Update. Details on our … Continue Reading

A33 Heavy Fuel

March 5, 2021

The A33 is being upgraded to support operation on spark ignited heavy fuel. The upgrades touch every part of the engine system; and many of the … Continue Reading

IntelliJect Software Version 1.9 Release

February 2, 2021

IntelliJect software version 1.9 is available. 1.9 supports all revisions of the IntelliJect hardware, including the upcoming revision 5. Features … Continue Reading

CE370 – Type E Pump Advisory Notice

September 5, 2019

A premature brush failure issue has been found in the CE370-07, -08, -10 Type E pumps. Work is underway to develop a procedure for inspection for the … Continue Reading

IntelliJect Hardware Revision 3

July 15, 2019

Power4Flight is announcing the next update to the IntelliJect electronic fuel injection hardware: revision 3. Revision 3 hardware adds the following … Continue Reading

IntelliJect Software Version 1.7 Release

July 15, 2019

Power4Flight is announcing the release of the 1.7 software version for the IntelliJect electronic fuel injection system. This release adds support for … Continue Reading

Announcing the A99 Engine

May 7, 2019

The A99 is an inline triple liquid cooled two-stroke engine with a total displacement of 99cc. Designed by Cobra Aero to take advantage of the latest … Continue Reading

Power4Flight - EFI UAV Engines© 2023 Power4Flight
202 Wasco Loop Rd
Hood River, OR 97031
Phone: 541.436.4299

Terms of Service

Return Policy

Privacy Policy

  • Email
  • Instagram
  • LinkedIn
  • YouTube

Copyright © 2023 · Power4Flight