Abstract: A wind turbine blade shell component is made by providing a plurality of first pultrusion plates formed of a first fiber material, and a plurality of second pultrusion plates formed of a second fiber material. The first and second pultrusion plates are stacked in a hybrid pattern that includes a first section containing a plurality of the first and second pultrusion plates having a length shorter than an entire length of a spar cap for a wind turbine blade shell, and a core section having a continuous unbroken length of the second fiber material corresponding to an entire length of the spar cap. The stacked pattern is arranged on blade shell materials in a mold for the blade shell component and is bonded with the blade shell materials to form the blade shell component.

Abstract: A wind turbine blade shell component is made by providing a plurality of first pultrusion plates formed of a first fiber material, and a plurality of second pultrusion plates formed of a second fiber material. The first and second pultrusion plates are stacked in a hybrid pattern that includes a first section containing a plurality of the first and second pultrusion plates having a length shorter than an entire length of a spar cap for a wind turbine blade shell, and a core section having a continuous unbroken length of the second fiber material corresponding to an entire length of the spar cap. The stacked pattern is arranged on blade shell materials in a mold for the blade shell component and is bonded with the blade shell materials to form the blade shell component.

Abstract: Rotor blades for a wind turbines include a structural support member disposed internal the rotor blade that extends for at least a portion of a rotor blade span length and an airfoil structure supported by the structural support member, the airfoil structure comprising a shell portion and at least one load-transferring exterior panel. The shell portion and the at least one load-transferring exterior panel combine to form an aerodynamic profile comprising a leading edge opposite a trailing edge and a pressure side opposite a suction side. Moreover, the shell portion and the at least one load-transferring exterior panel are independently connected to the structural support member.

Abstract: Rotor blade assembly and methods for forming rotor blade assemblies are provided. A rotor blade assembly includes a rotor blade including a shell and defining a pressure side, a suction side, a leading edge and a trailing edge each extending between a tip and a root. The rotor blade further defines a span and a chord. The shell includes an inner skin, an outer skin, and a core disposed between the inner skin and the outer skin. The rotor blade assembly further includes a reinforcement assembly bonded to the shell, the reinforcement assembly comprising a reinforcement core.

Abstract: Tools and methods are provided for scarfing rotor blade segments. A rotor blade segment includes a pressure side and a suction side. A tool includes a first guide configured for mounting on one of the pressure side or the suction side, the first guide including a first curved rail and a second curved rail spaced from the first curved rail. The tool further includes a second guide movably coupled to the first guide at a scarf angle, the second guide including a guide rail extending between and movable along the first curved rail and the second curved rail. The tool further includes a cutting device movably coupled to the second guide, the cutting device movable along the guide rail and operable to remove material from the one of the pressure side or the suction side.

Abstract: A spar assembly for a rotor blade of a wind turbine is disclosed. The spar assembly includes a first spar cap segment and a second spar cap segment. The first spar cap segment is configured on an interior surface of a first blade segment and the second spar cap segment is configured on an interior surface of a second blade segment. Each spar cap segment includes an end having a joint section that is joinable at a chord-wise joint. Each of the first and second joint sections includes a plurality of holes formed therein. Further, the spar assembly includes a plurality of pins inserted into the plurality of holes of the first and second joint sections to join the first and second blade segments so as to improve stiffness of the rotor blade.

Abstract: Rotor blades for a wind turbines include a structural support member disposed internal the rotor blade that extends for at least a portion of a rotor blade span length and an airfoil structure supported by the structural support member, the airfoil structure comprising a shell portion and at least one load-transferring exterior panel. The shell portion and the at least one load-transferring exterior panel combine to form an aerodynamic profile comprising a leading edge opposite a trailing edge and a pressure side opposite a suction side. Moreover, the shell portion and the at least one load-transferring exterior panel are independently connected to the structural support member.

Abstract: A spar assembly for a rotor blade of a wind turbine is disclosed. The spar assembly includes a first spar cap segment and a second spar cap segment. The first spar cap segment is configured on an interior surface of a first blade segment and the second spar cap segment is configured on an interior surface of a second blade segment. Each spar cap segment includes an end having a joint section that is joinable at a chord-wise joint. Each of the first and second joint sections includes a plurality of holes formed therein. Further, the spar assembly includes a plurality of pins inserted into the plurality of holes of the first and second joint sections to join the first and second blade segments so as to improve stiffness of the rotor blade.

Abstract: Rotor blade assembly and methods for forming rotor blade assemblies are provided. A rotor blade assembly includes a rotor blade including a shell and defining a pressure side, a suction side, a leading edge and a trailing edge each extending between a tip and a root. The rotor blade further defines a span and a chord. The shell includes an inner skin, an outer skin, and a core disposed between the inner skin and the outer skin. The rotor blade assembly further includes a reinforcement assembly bonded to the shell, the reinforcement assembly comprising a reinforcement core.

Abstract: Tools and methods are provided for scarfing rotor blade segments. A rotor blade segment includes a pressure side and a suction side. A tool includes a first guide configured for mounting on one of the pressure side or the suction side, the first guide including a first curved rail and a second curved rail spaced from the first curved rail. The tool further includes a second guide movably coupled to the first guide at a scarf angle, the second guide including a guide rail extending between and movable along the first curved rail and the second curved rail. The tool further includes a cutting device movably coupled to the second guide, the cutting device movable along the guide rail and operable to remove material from the one of the pressure side or the suction side.