Abstract: A wind turbine blade comprising a plurality of spar components extending along the longitudinal axis and providing the main bending stiffness of the wind turbine blade a major principal axis defining a structural pitch angle of at least 1° with respect to a chord line, and including: one or more suction-side spar caps each having a centre line; one or more pressure-side spar caps each having a centre line; and one or more shear webs distributed around a central shear web line and at least one of which being connected to first spar caps, wherein at least one suction-side spar cap centre lines is arranged with a first chordwise distance to the central shear web line, and at least one pressure-side spar cap centre lines is arranged with a second, different, chordwise distance to the central shear web line.

Abstract: A rotor blade assembly for a wind turbine includes a pressure side and a suction side extending between a leading edge and a trailing edge. A generally cylindrical blade root section has a flush root end configured to attach the rotor blade assembly to a hub. A plurality of span-wise extending root inserts are disposed around and molded into the cylindrical blade root section, with each root insert having an end face and defining an internally threaded bore configured for receipt of a bolt member for attaching the rotor blade assembly to the hub. A metallic flange is disposed at an end of one of the root inserts. The metallic flange is flush with the end faces of adjacent root inserts such that the metallic flange and end faces of the root inserts lie in a common flush plane of the root end.

Abstract: The present subject matter is directed to a rotor blade assembly having a rotor blade with a blade tip segment having a blade tip and a blade root segment having a blade root. The blade segments extend in opposite directions from a chord-wise joint. The blade tip segment includes a beam structure extending lengthways that structurally connects with the blade root segment via a receiving section. The assembly also includes a plurality of first bolt joints located at a first end of the beam structure for connecting with the receiving section of the blade root segment. The assembly also includes a lightning protection system with at least one lightning receptor coupled to a lightning receptor cable. The lightning receptor cable is routed from the blade tip to each of the plurality of first bolt joints and to the blade root.

Abstract: Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.

Abstract: The present subject matter is directed to a rotor blade assembly having a rotor blade with a blade tip segment having a blade tip and a blade root segment having a blade root. The blade segments extend in opposite directions from a chord-wise joint. The blade tip segment includes a beam structure extending lengthways that structurally connects with the blade root segment via a receiving section. The assembly also includes a plurality of first bolt joints located at a first end of the beam structure for connecting with the receiving section of the blade root segment. The assembly also includes a lightning protection system with at least one lightning receptor coupled to a lightning receptor cable. The lightning receptor cable is routed from the blade tip to each of the plurality of first bolt joints and to the blade root.

Abstract: A rotor blade assembly for a wind turbine includes a pressure side and a suction side extending between a leading edge and a trailing edge. A generally cylindrical blade root section has a flush root end configured to attach the rotor blade assembly to a hub. A plurality of span-wise extending root inserts are disposed around and molded into the cylindrical blade root section, with each root insert having an end face and defining an internally threaded bore configured for receipt of a bolt member for attaching the rotor blade assembly to the hub. A metallic flange is disposed at an end of one of the root inserts. The metallic flange is flush with the end faces of adjacent root inserts such that the metallic flange and end faces of the root inserts lie in a common flush plane of the root end.

Abstract: The present disclosure is directed to a system and method for securing a lightning protection cable (e.g. a conductor) of a lightning protection system within a wind turbine rotor blade. The lightning protection system includes a plurality of lightning receptors configured along either or both of the pressure or suction sides of the rotor blade. The lightning receptors are connected via the conductor so as to form a conductive circuit. Further, a cover assembly defining a passageway therethrough is configured to receive at least a portion of the conductor along a length thereof. Thus, the cover assembly can be secured to an inner surface of the internal cavity so as to maintain a location of the conductor. Accordingly, the conductor is free to move within the cover assembly since the wire is not directly attached to the rotor blade.

Abstract: A system and method for mounting a component to an internal web of a wind turbine blade includes, at a first mounting location on the internal web, at least one through-hole defined through the internal web. A bushing is located within the through-hole and is encased within an adhesive applied between the bushing and a wall of the through-hole. A plate is attached to each of the opposite panels of the internal web at the mounting location against an end face of the bushing, with each plate having a hole therein that is aligned with the through-hole. For mounting the component at the mounting location, a bolt is passed completely through the plates and bushing for attachment of a frame of the component to one of the plates.

Abstract: Aerodynamic root adapters for rotor blades include an interior support section having a first end that connects to a root end of the rotor blade and a second end that connects to a rotor hub of the wind turbine, and, an aerodynamic exterior section supported by the interior support section. The aerodynamic exterior section thereby extends an aerodynamic profile of the rotor blade beyond the root end of the rotor blade to at least partially between the root end of the rotor blade and the rotor hub when the aerodynamic root adapter is connected thereto.

Abstract: Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.

Abstract: Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.

Abstract: A system and method for mounting a component to an internal web of a wind turbine blade includes, at a first mounting location on the internal web, at least one through-hole defined through the internal web. A bushing is located within the through-hole and is encased within an adhesive applied between the bushing and a wall of the through-hole. A plate is attached to each of the opposite panels of the internal web at the mounting location against an end face of the bushing, with each plate having a hole therein that is aligned with the through-hole. For mounting the component at the mounting location, a bolt is passed completely through the plates and bushing for attachment of a frame of the component to one of the plates.

Abstract: The present disclosure is directed to a system and method for securing a lightning protection cable (e.g. a conductor) of a lightning protection system within a wind turbine rotor blade. The lightning protection system includes a plurality of lightning receptors configured along either or both of the pressure or suction sides of the rotor blade. The lightning receptors are connected via the conductor so as to form a conductive circuit. Further, a cover assembly defining a passageway therethrough is configured to receive at least a portion of the conductor along a length thereof. Thus, the cover assembly can be secured to an inner surface of the internal cavity so as to maintain a location of the conductor. Accordingly, the conductor is free to move within the cover assembly since the wire is not directly attached to the rotor blade.

Abstract: Aerodynamic root adapters for rotor blades include an interior support section having a first end that connects to a root end of the rotor blade and a second end that connects to a rotor hub of the wind turbine, and, an aerodynamic exterior section supported by the interior support section. The aerodynamic exterior section thereby extends an aerodynamic profile of the rotor blade beyond the root end of the rotor blade to at least partially between the root end of the rotor blade and the rotor hub when the aerodynamic root adapter is connected thereto.

Abstract: In one aspect, a rotor blade for a wind turbine includes a body extending between a root end and a tip end. The body may include a root portion extending from the root end. The root portion may include an inner surface defining an inner circumference. In addition, the rotor blade may include a root stiffener disposed at least partially within the root portion of the body. The root stiffener may include a plurality of arms extending radially from the inner surface and may be configured to extend circumferentially around only a portion of the inner circumference of the root portion.

Abstract: Joints for connecting a first blade segment to a second blade segment of a wind turbine rotor blade include a first bolt comprising a first proximal end connected to the first blade segment and a first distal end connected to the second blade segment, a second bolt comprising a second proximal end connected to the first blade segment and a second distal end connected to the second blade segment, and a third bolt comprising a third proximal end connected to the first blade segment and a third distal end connected to the third blade segment. At least two of the first bolt, the second bolt and the third bolt differ in size, and a first distance between the first bolt and the second bolt is different than a second distance between the second bolt and the third bolt.

Abstract: Methods for forming rotor blades, rotor blade mold assemblies, and cores for rotor blade mold assemblies are disclosed. A method includes providing a first shell substrate on a first mold, providing a generally hollow core on the first shell substrate, providing a second shell substrate on the generally hollow core, and providing a second mold on the second shell substrate. The method further includes flowing a resin into a mold interior defined between the first mold and the second mold.

Abstract: A method of assembling a rotor blade for use with a wind turbine. The method includes coupling a first sparcap to at least one first panel wall to form a first blade section, wherein the first sparcap has a first chordwise width. A second sparcap is coupled to at least one second panel wall to form a second blade section. The second sparcap has a second chordwise width that is larger than the first chordwise width. The first blade section is coupled to the second blade section to form the rotor blade.

Abstract: An active flow control system for use with a wind turbine is provided. The wind turbine includes at least one blade. The active flow control system includes an air distribution system at least partially defined within said at least one blade. The air distribution system includes at least one aperture defined through the at least one blade. An aperture control system is in operational control communication with the air distribution system. The aperture control system includes an actuator at least partially positioned within the at least one blade and configured to control a flow of air discharged through the at least one aperture.

Abstract: A wind turbine blade includes a pressure side shell member with an internal side spar cap, and a suction side shell member with an internal side spar cap. A box-shaped shear web assembly spans between the spar caps and has a generally hollow interior volume. The shear web assembly includes end walls affixed to a respective spar cap and spaced-apart side walls extending transversely between the end walls. The end walls and side walls define a continuous box-shaped assembly structurally interposed between the spar caps. Methods are also provided for making the box-shaped shear web assembly.