Abstract: The present disclosure is directed to an apparatus for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold, and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis.

Abstract: The present disclosure is directed to an apparatus and method for manufacturing a composite component. The apparatus includes a mold onto which the composite component is formed. The mold is disposed within a grid defined by a first axis and a second axis. The apparatus further includes a first frame assembly disposed above the mold and a plurality of machine heads coupled to the first frame assembly within the grid in an adjacent arrangement along the first axis. At least one of the mold or the plurality of machine heads is moveable along the first axis, the second axis, or both. At least one of the machine heads of the plurality of machine heads is moveable independently of one another along a third axis. A second frame assembly is moveable above the mold along the first axis, the second axis, or both. The second frame assembly includes a holding device. The holding device affixes to and releases from an outer skin to place and displace the outer skin at the mold.

Abstract: Rotor blade panels, along with methods of their formation, are provided. The rotor blade panel may include one or more fiber-reinforced outer skins having an inner surface; and, a plurality of reinforcement structures on the inner surface of the one or more fiber-reinforced outer skins, where the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited. The reinforcement structure includes, at least, a first composition and a second composition, with the first composition being different than the second composition.

Abstract: Wind turbine rotor blade components including pultruded rods and methods of manufacturing the same are disclosed. More specifically, the rotor blade component includes a plurality of pultruded rods housed within an enclosed primary outer casing. The enclosed primary outer casing includes a hollow interior, a root end, and an opposing tip. As such, each of the plurality of pultruded rods is received within the enclosed primary outer casing and secured therein via a first resin material. Further, an arrangement of the plurality of pultruded rods within the primary outer casing and a relationship of a maximum dimension of each of the plurality of pultruded rods and a maximum dimension of the enclosed primary outer casing are configured to maximize flexibility of the rotor blade component.

Abstract: A deployable aerodynamic component configured to be mounted to a wind turbine. The wind turbine includes at least one rotor blade. The deployable aerodynamic component configured to be positioned in front of an inner portion of the at least one rotor blade, and is structurally configured to cover a substantial portion of the inner portion of the at least one rotor blade in a wind direction during deployment of the deployable aerodynamic component and to allow the passage therethrough of an incoming wind when non-deployed. Further described is a wind turbine including the above-described deployable aerodynamic component and method for aerodynamic performance enhancement of an existing wind turbine, wherein the method includes mounting the above-described deployable aerodynamic component to a wind turbine.

Abstract: A method and mold assembly for manufacturing a rotor blade component of a wind turbine is disclosed. The mold assembly includes a mold body that is divided into a plurality of mold zones, with each mold zone having a sensor for sensing a temperature thereof. Further, a composite material schedule is provided for each of the mold zones. Thus, the method includes placing composite material onto the mold body according to the composite material schedule and supplying a resin material to each mold zone of the mold body. The method also includes implementing a cure cycle for the component that includes supplying heat to each of the mold zones, continuously receiving signals from the sensors from the mold zones, and dynamically controlling via machine learning the supplied heat to each mold zone based on the sensor signals and the composite material schedule.

Abstract: The present disclosure is directed to a rotor blade assembly for a wind turbine having a first rotor blade segment with a first spar cap segment and a second rotor blade segment with a second spar cap segment. The first and second spar cap segments are arranged together at an interface and are constructed of a composite material. Further, the rotor blade assembly includes a joint assembly at the interface of the first and second spar cap segments. The joint assembly is constructed of a first metal joint secured to the first spar cap segment and a second metal joint secured to second spar cap segment. Moreover, the first and second metal joints are welded together at a weld area.

Abstract: The present subject matter is directed to methods for manufacturing rotor blades and/or components thereof of a wind turbine. In one embodiment, the method includes forming the rotor blade component and covering at least a portion of the rotor blade component with at least one coating material. In addition, the coating material includes at least one additive having a changeable pigment. After the component is formed, the method includes inspecting the rotor blade component for defects. After inspection, the method further includes activating the additive to change the pigment from a transparent finish to a colored finish.

Abstract: The present disclosure is directed to a method of manufacturing a rotor blade component of a wind turbine is disclosed. The method includes placing at least one first pultruded member into a curved rotor blade component mold. More specifically, the first pultruded member includes at least one design characteristic configured to allow the first pultruded member to sit substantially flush against an inner surface of the curved rotor blade component mold. The method also includes placing at least one second pultruded member atop the at least one first pultruded member and infusing the first and second pultruded members together to form the rotor blade component.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed to a rotor blade that includes a shell defining an interior cavity. The rotor blade also includes exterior surfaces defining a pressure side, a suction side, a leading edge, and a trailing edge. Each of the pressure side, the suction side, the leading edge, and the trailing edge extends between a tip and a root. The shell defines a span and a chord. A shear web is positioned in the interior cavity and coupled to the shell. The shear web includes a lattice structure.

Abstract: The present disclosure is directed to a vortex generator configured for mounting to either of a suction side or a pressure side of a rotor blade. The vortex generator includes a base portion having a contour in an uninstalled state that substantially aligns with or conforms to a contour of a plurality of locations of either on the suction side or the pressure side of the rotor blade. Further, the vortex generator includes a protrusion member extending upwardly from the base portion. The protrusion member includes a plurality of tines separated by at least one slit. Moreover, the base portion and the protrusion member are constructed of a rigid material. In addition, the vortex generator includes a flexible coating material configured at least partially around the base portion and/or within or around the at least one slit.

Abstract: A rotor blade of a wind turbine having a pultruded spar cap is disclosed. The rotor blade includes a blade root and a blade tip. The blade root includes at least one root insert. The rotor blade also includes at least one spar cap constructed of a plurality of pultruded members grouped together to form one or more layers from the blade tip towards the blade root. Further, the pultruded members separate into one or more pultruded member bundles as the spar cap approaches the blade root. The pultruded member bundles fit within the root insert, along with the blade bolts, such that compression and tension loads of the rotor blade are transferred through the pultruded members.

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: Transportation assemblies for rotor blades are provided. A transportation assembly includes a protection cap including a nose portion and a plurality of sidewall portions extending from the nose portion, the protection cap having a generally U-shaped cross-sectional profile. The transportation assembly further includes a restraint assembly including a first protrusion and a second protrusion each extending from the protection cap, the first protrusion and the second protrusion spaced apart along a width of the protection cap.

Abstract: A rotor blade of a wind turbine having a pultruded spar cap is disclosed. The rotor blade includes a blade root and a blade tip. The blade root includes at least one root insert. The rotor blade also includes at least one spar cap constructed of a plurality of pultruded members grouped together to form one or more layers from the blade tip towards the blade root. Further, the pultruded members separate into one or more pultruded member bundles as the spar cap approaches the blade root. The pultruded member bundles fit within the root insert, along with the blade bolts, such that compression and tension loads of the rotor blade are transferred through the pultruded members.

Abstract: A deployable aerodynamic component configured to be mounted to a wind turbine. The wind turbine includes at least one rotor blade. The deployable aerodynamic component configured to be positioned in front of an inner portion of the at least one rotor blade, and is structurally configured to cover a substantial portion of the inner portion of the at least one rotor blade in a wind direction during deployment of the deployable aerodynamic component and to allow the passage therethrough of an incoming wind when non-deployed. Further described is a wind turbine including the above-described deployable aerodynamic component and method for aerodynamic performance enhancement of an existing wind turbine, wherein the method includes mounting the above-described deployable aerodynamic component to a wind turbine.

Abstract: A transportation system for transporting rotor blades includes a rotor blade fixture configured to support one or more rotor blades. The rotor blade fixture has a first end, and a second end opposed to the first end. The first end is configured for mounting to a root end of a first rotor blade. The rotor blade fixture has a mid-span support located between about 50% and about 80% of a rotor blade span of the first rotor blade. The mid-span support is configured for supporting a mid-span portion of the rotor blade. The rotor blade fixture is configured to mount to a supporting surface so that a portion of the rotor blade fixture and the first rotor blade overhangs the supporting surface. The one or more rotor blades are supported at the root end and at a mid-span location located between about 50% and 80% of the rotor blade span.

Abstract: A deployable aerodynamic component configured to be mounted to a wind turbine. The wind turbine includes at least one rotor blade. The deployable aerodynamic component configured to be positioned in front of an inner portion of the at least one rotor blade, and is structurally configured to cover a substantial portion of the inner portion of the at least one rotor blade in a wind direction during deployment of the deployable aerodynamic component and to allow the passage therethrough of an incoming wind when non-deployed. Further described is a wind turbine including the above-described deployable aerodynamic component and method for aerodynamic performance enhancement of an existing wind turbine, wherein the method includes mounting the above-described deployable aerodynamic component to a wind turbine.