Abstract: The present disclosure is directed to embodiments of a tower structure with at least partially additively manufactured, stacked tower sections. Embodiments of the tower structure have a plurality of stacked tower sections, wherein at least one tower section of the plurality of stacked tower sections includes a wall element having one or more printed layers, and a base holding thereon the one or more printed layers. The present disclosure also is directed to a method of manufacturing a tower structure using a stacked tower sections and additive manufacturing. Embodiments of the method include forming a base of poured concrete or cast material, printing and depositing one or more printed layers to form a wall element, and stacking the plurality of tower sections to form the tower structure.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

Abstract: The present application presents novel systems and methods for tracking reinforcement member placement in an additively manufactured structure that are simple, accurate, non-labor-intensive, and cost-effective. The present application also presents a novel method of manufacturing a tower structure comprising: depositing, via an additive printing system, a first printed layer of a wall with a printhead assembly, the wall at least partially circumscribing a vertical axis of the tower structure; positioning a first reinforcement member on the first printed layer; depositing, via the additive printing system, a second printed layer of the wall with the printhead assembly on the first reinforcement member, the second printed layer configured to hold a second reinforcement member thereon; and determining, via an optical sensor of the additive printing system, a position for placing the second reinforcement member based on the first reinforcement member positioning.

Abstract: The present application presents novel systems and methods for tracking reinforcement member placement in an additively manufactured structure that are simple, accurate, non-labor-intensive, and cost-effective. The present application also presents a novel method of manufacturing a tower structure comprising: depositing, via an additive printing system, a first printed layer of a wall with a printhead assembly, the wall at least partially circumscribing a vertical axis of the tower structure; positioning a first reinforcement member on the first printed layer; depositing, via the additive printing system, a second printed layer of the wall with the printhead assembly on the first reinforcement member, the second printed layer configured to hold a second reinforcement member thereon; and determining, via an optical sensor of the additive printing system, a position for placing the second reinforcement member based on the first reinforcement member positioning.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

Abstract: A gear system includes a carrier having a first portion and a separate, second portion and a plurality of pin shafts extending from the first portion of the carrier. Each of the plurality of pin shafts includes a first end and a second end. As such, the first ends are integrally formed with the first portion of the carrier. The first and second portions are arranged on opposing sides of the plurality of pin shafts and are spaced apart such that the first and second portions do not contact each other. Further, the second portion of the carrier defines an end plate that is secured to the second ends of the plurality of pin shafts. The gear system also includes a plurality of gears mounted to the plurality of pin shafts, with each of the plurality of gears arranged so as to rotate around one of the plurality of pin shafts.

Abstract: A system for manufacturing a blade component of a rotor blade of a wind turbine includes a blade mold of the rotor blade, at least one blade skin arranged atop the blade mold, and a computer numeric control (CNC) device comprising a printer head and a scanning device. The printer head is configured for printing and depositing a material onto the at least one blade skin to form the blade component. The scanning device includes a processor and a scanner communicatively coupled to the processor.

Abstract: A method of joining first and second blade components of a rotor blade of a wind turbine includes providing corresponding first and second positioning elements at an interface of the first and second blade components. The method also includes aligning and securing the first positioning element of the first blade component with the second positioning element of the second blade component so as to temporarily secure the first and second blade components together. Further, the corresponding first and second positioning elements maintain a desired spacing between the first and second blade components. Moreover, the method includes permanently securing the first and second blade components together such that the desired spacing is maintained between the first and second blade components.

Abstract: A system for manufacturing a panel includes a support frame, a first caul plate arranged atop the support frame, a second caul plate arranged atop the first caul plate, and a heating assembly having a housing defining an inlet and an outlet. The housing includes one or more heaters. The heater(s) is configured to generate heat and the housing is configured to generate a first pressurized gas film. Thus, one or more layers of material to be consolidated may be placed between the first and second caul plates and drawn through the heating assembly as the heating assembly applies pressure to the one or more layers of material to be consolidated via the first pressurized gas film in combination with applying the heat via the one or more heaters, thereby consolidating the panel.

Abstract: A method for forming an article includes placing at least one forming tool of the article adjacent to a substrate, the at least one forming tool having a predefined shape and/or height. The method also includes extruding a bead of material from a printer head of a print head assembly directly into or onto the forming tool(s) of the article so as to increase a height of the bead of material via the forming tool(s), thereby reducing or eliminating a number of extruded layers of the material. Further, the method includes allowing the material to solidify to form the article. Thus, by using the forming tool(s), multiple printed layers of the material can be eliminated or reduced.

Abstract: A gear system includes a carrier having a first portion and a separate, second portion and a plurality of pin shafts extending from the first portion of the carrier. Each of the plurality of pin shafts includes a first end and a second end. As such, the first ends are integrally formed with the first portion of the carrier. The first and second portions are arranged on opposing sides of the plurality of pin shafts and are spaced apart such that the first and second portions do not contact each other. Further, the second portion of the carrier defines an end plate that is secured to the second ends of the plurality of pin shafts. The gear system also includes a plurality of gears mounted to the plurality of pin shafts, with each of the plurality of gears arranged so as to rotate around one of the plurality of pin shafts.

Abstract: A method for controlling loads of a wind turbine includes receiving sensor signals from one or more sensors being indicative of a movement of a nacelle of the wind turbine from a reference point. More particularly, the movement corresponds, at least, to a tilt and/or a displacement of the wind turbine tower and/or nacelle. The method also includes generating a deflection profile of the tower along its overall length from a bottom end to a top end thereof based on the sensor signals. Further, the method includes determining at least one of a thrust or a tower load of the wind turbine from the deflection profile. In addition, the method includes implementing a control action for the wind turbine based on the thrust and/or the tower load.

Abstract: A method for controlling loads of a wind turbine includes receiving sensor signals from one or more sensors being indicative of a movement of a nacelle of the wind turbine from a reference point. More particularly, the movement corresponds, at least, to a tilt and/or a displacement of the wind turbine tower and/or nacelle. The method also includes generating a deflection profile of the tower along its overall length from a bottom end to a top end thereof based on the sensor signals. Further, the method includes determining at least one of a thrust or a tower load of the wind turbine from the deflection profile. In addition, the method includes implementing a control action for the wind turbine based on the thrust and/or the tower load.