Abstract: A method for in-line processing of pre-formed pultruded products may generally include transporting a pre-formed pultruded product in a processing direction along a travel path, wherein the product includes a combination of fibers and resin and wherein the product extends lengthwise in the processing direction and defines an initial width in a widthwise direction. The method may also include roughening an outer surface of the pre-formed pultruded product as the product is being transported in the processing direction along the travel path and cutting the pre-formed pultruded product lengthwise in the processing direction to form first and second pultruded plates as the product is being transported in the processing direction along the travel path, wherein each of the first and second pultruded plates defines a width in the widthwise direction that is less than the initial width of the product.

Abstract: A rotor blade may generally include a shell forming an outer skin of the blade, with the shell defining a chordwise curvature. The rotor blade may also include a spar cap extending within the shell along a spanwise direction of the blade. The spar cap may be formed from an assembly of pre-cured laminate plates. In addition, the rotor blade may include an interior shelf positioned directly between the shell and the spar cap. The interior shelf may include an outer surface extending adjacent to the shell and an inner surface opposite the outer surface. The outer surface may define a curved profile generally corresponding to a portion of the chordwise curvature of the shell and the inner surface may define a planar surface along which the spar cap extends in a chordwise direction of the blade. The interior shelf may correspond to a pre-fabricated insert for the blade.

Abstract: The present disclosure is directed to a root assembly for a rotor blade of a wind turbine and methods of manufacturing same. The root assembly includes a blade root section having an inner sidewall surface and an outer sidewall surface separated by a radial gap, a plurality of root inserts spaced circumferentially within the radial gap, and a plurality of spacers configured between one or more of the root inserts. Further, each of the root inserts includes at least one bushing surrounded by a pre-cured or pre-consolidated composite material. In addition, the spacers are constructed of a pre-cured or pre-consolidated composite material.

Abstract: The present disclosure is directed to a root assembly for a rotor blade of a wind turbine and methods of manufacturing same. The root assembly includes a blade root section having an inner sidewall surface and an outer sidewall surface separated by a radial gap, a plurality of root inserts spaced circumferentially within the radial gap, and a plurality of spacers configured between one or more of the root inserts. Further, each of the root inserts includes at least one bore hole surrounded by a pre-cured or pre-consolidated composite material. In addition, the pultruded spacers are constructed of a pre-cured or pre-consolidated composite material.

Abstract: The present disclosure is directed to a method for assembling a modular rotor blade of a wind turbine. The method includes providing a pre-formed blade root section and a pre-formed blade tip section of the rotor blade. Further, the blade root section includes one or more spar caps extending in a generally span-wise direction. Another step includes providing at least one pre-formed blade segment of the rotor blade. The method also includes mounting the at least one blade segment around the one or more spar caps of the blade root section, wherein the at least one blade segment includes a chord-wise cross-section having multiple joints, wherein at least one joint is located on at least one of a pressure side surface or a suction side surface. In addition, the method also includes joining the blade tip section to at least one of the one or more spar caps or the at least one blade segment.

Abstract: The present disclosure is directed to a modular rotor blade for a wind turbine and methods of assembling same. The rotor blade includes a blade root section, a blade tip section, at least one leading edge segment having a forward pressure side surface and a forward suction side surface, and at least one trailing edge segment having an aft pressure side surface and an aft suction side surface. Further, the leading edge segment and the trailing edge segment are arranged between the blade root section and the blade tip section in a generally span-wise direction. In addition, the leading edge segment and the trailing edge segment are joined at a pressure side seam and a suction side seam.

Abstract: The present disclosure is directed to a pre-formed, continuous structural component for use in assembling a modular rotor blade for a wind turbine. Further, the structural component provides support to the modular rotor blade during operation. The pre-formed structural component includes a root portion and a body portion. The root portion is configured for mounting the structural component to a blade root section of the rotor blade. The body portion is configured to extend in a generally span-wise direction. Further, the body portion defines a predetermined cross-section having a flatback portion with a first end and a second end. In addition, the first and second ends each have a flange extending perpendicularly therefrom. Thus, each flange defines a mounting surface for one or more blade segments.

Abstract: The present disclosure is directed to a pre-formed blade root section for a modular rotor blade of a wind turbine and methods of manufacturing same. More specifically, the blade root section includes a root end portion and one or more longitudinal spar caps co-infused with the root end portion and extending in a generally span-wise direction. In addition, the root end portion includes a first end and second end, wherein the first end is configured for mounting the rotor blade to a rotor of the wind turbine.

Abstract: A platform cooling arrangement in a turbine rotor blade having a platform that includes an interior cooling passage formed therein. The platform cooling arrangement may include: a main plenum residing just inboard of the planar topside and extending from an aft position to a forward position within one of the pressure side and the suction side of the platform, the main plenum having a longitudinal axis that is approximately parallel to the planar topside; a supply plenum that extends between the main plenum and the interior cooling passage; and a plurality of cooling apertures, each cooling aperture extending from one of the pressure side and the suction side slashface to a connection with the main plenum.

Abstract: A platform cooling arrangement for a turbine rotor blade having a platform and an interior cooling passage and, in operation, a high-pressure coolant region and a low-pressure coolant region, wherein the platform includes a topside, which extends from the airfoil to a pressure side slashface, and an underside. The platform cooling arrangement may include: an airfoil manifold that resides near the junction of the pressure face of the airfoil and the platform; a slashface manifold that resides near the pressure side slashface; a high-pressure connector that connects the airfoil manifold to a high-pressure coolant region of the interior cooling passage; a low-pressure connector that connects the slashface manifold to a low-pressure coolant region of the interior cooling passage; cooling apertures that extend from a starting point along the pressure side slashface to a connection with the airfoil manifold, bisecting the slashface manifold therebetween; and a plurality of non-integral plugs.

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: A configuration of cooling channels through the interior of a turbine rotor blade, the turbine rotor blade including a platform at an interface between an airfoil and a root. In one embodiment, the configuration of cooling channels includes: an interior cooling passage that is configured to extend from a connection with a coolant source in the root to the interior of the airfoil; a platform cooling channel that traverses at least a portion of the platform; a turndown extension that includes a first section, which comprises a connection with the platform cooling channel, and a second section, which comprises a radially oriented cooling channel; and a connector that extends from a connector opening formed through an outer face of the root to a connection with the interior cooling passage and, therebetween, bisects the second section of the turndown extension.

Abstract: A configuration of cooling channels through the interior of a turbine rotor blade, the turbine rotor blade including a platform at an interface between an airfoil and a root. In one embodiment, the configuration of cooling channels includes: an interior cooling passage that is configured to extend from a connection with a coolant source in the root to the interior of the airfoil; a platform cooling channel that traverses at least a portion of the platform; a turndown extension that includes a first section, which comprises a connection with the platform cooling channel, and a second section, which comprises a radially oriented cooling channel; and a connector that extends from a connector opening formed through an outer face of the root to a connection with the interior cooling passage and, therebetween, bisects the second section of the turndown extension.

Abstract: A joint for connecting a first blade segment and a second blade segment of a wind turbine rotor blade is disclosed. The joint includes a body, the body including an outer surface and an inner surface. The outer surface has an aerodynamic contour that generally corresponds to an aerodynamic contour of the first blade segment and the second blade segment. The body includes a pressure side and a suction side extending between a leading edge and a trailing edge. In some embodiments, the joint further includes a channel defined in the outer surface of the body. The channel includes a generally continuous base wall extending between opposing sidewalls. The inner surface includes the base wall. In other embodiments, the joint further includes a channel defined in the body, and a shell extending from the body in a generally span-wise direction.

Abstract: A platform cooling arrangement for a turbine rotor blade having a platform and an interior cooling passage and, in operation, a high-pressure coolant region and a low-pressure coolant region, wherein the platform includes a topside, which extends from the airfoil to a pressure side slashface, and an underside. The platform cooling arrangement may include: an airfoil manifold that resides near the junction of the pressure face of the airfoil and the platform; a slashface manifold that resides near the pressure side slashface; a high-pressure connector that connects the airfoil manifold to a high-pressure coolant region of the interior cooling passage; a low-pressure connector that connects the slashface manifold to a low-pressure coolant region of the interior cooling passage; cooling apertures that extend from a starting point along the pressure side slashface to a connection with the airfoil manifold, bisecting the slashface manifold therebetween; and a plurality of non-integral plugs.

Abstract: A platform cooling arrangement in a turbine rotor blade having a platform that includes an interior cooling passage formed therein. The platform cooling arrangement may include: a main plenum residing just inboard of the planar topside and extending from an aft position to a forward position within one of the pressure side and the suction side of the platform, the main plenum having a longitudinal axis that is approximately parallel to the planar topside; a supply plenum that extends between the main plenum and the interior cooling passage; and a plurality of cooling apertures, each cooling aperture extending from one of the pressure side and the suction side slashface to a connection with the main plenum.