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 rotor blade assembly for a wind turbine having a rigid root insert is disclosed. The rotor blade assembly includes a blade root section having an end face with a substantially annular cross-section defined by an outer sidewall surface and an inner sidewall surface. The end face is configured to attach the rotor blade assembly to a hub. The rotor blade assembly includes a radial bore hole provided a predetermined span-wise distance from the end face and extending between the sidewall surfaces and a longitudinal bore hole provided between the sidewall surfaces and extending from the end face to the radial bore hole. The rigid root insert is disposed within the longitudinal bore hole and extends from the end face to the radial bore hole. As such, the rigid root insert is configured to increase the stiffness of the blade root section when the rotor blade assembly is attached to the hub with bolts that extend into and through the radial bore hole and the longitudinal bore hole.

Abstract: The present subject matter is directed to a method for operating a wind turbine. The method includes calculating one or more blade root loads, e.g. a blade root resultant moment, of at least one rotor blade of the wind turbine. Another step includes estimating a span-wise loading of the rotor blade based at least partially on the one or more blade root loads. The method also includes determining a deformation margin of the rotor blade based at least partially on the span-wise loading and one or more estimated deformations occurring on the rotor blade. Another step includes controlling the wind turbine based on the deformation margin.

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 blades for 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, an airfoil structure supported by the structural support member, and a support flange connecting the airfoil structure to the structural support member. The support flange includes a first wall connected to the structural support member, a second wall connected to the airfoil structure, and a connection wall that extends between the first wall and the second wall.

Abstract: The present disclosure is directed to spar caps for wind turbine rotor blades and methods of manufacturing same. The spar cap includes a plurality of plies having varying lengths that are arranged in a tapered configuration. Further, the tapered configuration includes at least an upper portion and a lower portion. The upper portion is configured for attachment to at least one of a pressure side or a suction side of the rotor blade. Further, one or more plies of the upper and lower portions tapers towards an intermediate ply configured between the upper and lower portions of the spar cap. In addition, the intermediate ply has a length that is shorter than the plies in the upper and lower portions.

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: Rotor blade components for wind turbines having interlocking edges and methods of manufacturing same are disclosed. In one aspect of the present disclosure, the rotor blade component includes a plurality of pultruded members arranged in one or more layers. Each of the pultruded members are constructed of a plurality of fibers joined together via a cured resin material. Further, each of the plurality of pultruded members includes one or more interlocking edges. Thus, adjacent pultruded members may be aligned via corresponding interlocking edges. The pultruded members are further secured together to create a single structural member.

Abstract: Methods of manufacturing rotor blade components for a wind turbine using pre-cured, prefabricated plates constructed of multiple fiber materials are disclosed. In one aspect of the present disclosure, the method includes providing a plurality of pultruded members. Each of the pultruded members includes, at least, first and second fiber materials, wherein the first and second fiber materials include at least one of different sizes or different types of fiber materials. Another step includes arranging the plurality of pultruded members into one or more layers. A further step includes joining the layers of pultruded members together to form the rotor blade component.

Abstract: Methods of manufacturing spar caps for a rotor blade of a wind turbine are disclosed. The method includes providing a plurality of pultrusions constructed of one or more fibers or fiber bundles cured via a resin material. Another step includes tapering the ends of the pultrusions at a predetermined angle. The method also includes arranging the tapered pultrusions in a mold of the spar cap. The method also includes joining the plurality of pultrusions together so as to form the spar cap.

Abstract: A spar cap for a rotor blade of a wind turbine is disclosed. The rotor blade includes a blade root and a blade tip, leading and trailing edges, pressure and suction sides, and at least one spar cap configured on an internal surface of either or both the pressure or suction sides. The spar cap includes one or more layers of a first material and a second conductive material contacting at least one of the layers of the first material. Further, the conductive material is different than the first material. Thus, the conductive material is configured with the first material so as to create an equipotential spar cap.

Abstract: A wind turbine blade has an upper shell member and a lower shell member bonded at a leading and trailing edge of the blade with a bond paste applied between respective forward and rearward edges of the shell members. At least one of the shell members includes a first inspection window defined therein along one of the leading edge or trailing edge at a location corresponding at least to a design minimum bond width of the bond paste applied at the respective leading edge or trailing edge. The inspection window provides a visible access through the shell member such that a visible indication is generated through the inspection window when bond paste is injected and reaches the minimum bond width location in the chord-wise direction.

Abstract: The present disclosure is directed to a rotor blade assembly for a wind turbine that controls pitch bearing load distribution. The assembly includes a rotor blade having a body shell extending between a blade root and tip, a pitch bearing at an interface between the blade root and a hub of the wind turbine, and plurality of blade bolts coupling the blade root to the hub through the pitch bearing. The pitch bearing includes an outer bearing race and an inner bearing race rotatable relative to the outer race. Thus, in one embodiment, the blade bolts couple the blade root to the hub through the inner race of the pitch bearing. Further, each of the blade bolts has a first end and a second end defining a length therebetween and at least two of the blade bolts have varying lengths so as to distribute loads experienced by the pitch bearing.

Abstract: A rotor blade for a wind turbine is disclosed. The rotor blade may generally include a shell having a pressure side and a suction side. The shell may define an outer surface along the pressure and suction sides over which an airflow travels. The rotor blade may also include a spoiler having a fixed end and a free end. The fixed end is connected to the outer surface so as to enable a hinge action, such as a living hinge. The free end includes a top flange and a bottom flange configured to engage opposite sides of the shell and is pivotal relative to the fixed end between a recessed position and an elevated position. The free end has a range of motion limited by contact of the top flange and the bottom flange with the shell. Further, the spoiler is configured to separate the airflow from the outer surface when the spoiler is in the elevated position.

Abstract: Methods of manufacturing rotor blades for a wind turbine and rotor blades produced in accordance with such methods are disclosed. In one embodiment, the method includes forming a first spar cap of the rotor blade from a first resin material. Another step includes placing the first spar cap within a first shell mold of the rotor blade. A further step includes infusing a second resin material into the first shell mold to form a first shell member of the rotor blade. Thus, at least a portion of the first spar cap is infused within the first shell member. Further, the second resin material is different than the first resin material. The method also includes infusing the second resin material into a second shell mold to form a second shell member of the rotor blade. Another step includes bonding the first and second shell members together so as to form the rotor blade.

Abstract: Methods of manufacturing rotor blade components for a wind turbine and rotor blade components produced in accordance with such methods are disclosed. In one embodiment, the method generally includes providing a mold of the rotor blade component; coating at least a portion of an interior surface of the mold with an elastomeric material; inserting a foam material within the mold; and, removing the rotor blade component from the mold, wherein the elastomeric material forms a cover skin around at least a portion of the rotor blade component. In an alternative embodiment, the method includes providing at least one support member defining a profile for the rotor blade component on a mold surface; coating at least a portion of the support member with an elastomeric material; and, allowing the elastomeric material to cure on the mold surface so as to form the rotor blade component.

Abstract: A rotor blade for a wind turbine is disclosed. The rotor blade may generally include a shell having a pressure side and a suction side. The shell may define an outer surface along the pressure and suction sides over which an airflow travels. The rotor blade may also include a spoiler having a fixed end and a free end. The fixed end is connected to the outer surface so as to enable a hinge action, such as a living hinge. The free end includes a top flange and a bottom flange configured to engage opposite sides of the shell and is pivotal relative to the fixed end between a recessed position and an elevated position. The free end has a range of motion limited by contact of the top flange and the bottom flange with the shell. Further, the spoiler is configured to separate the airflow from the outer surface when the spoiler is in the elevated position.

Abstract: Rotor blades for a wind turbines include a shell having a pressure side and a suction side and a plurality of surface features disposed adjacent at least one of the pressure side and the section side. The plurality of surface features is further moveable between a spoiler position and a vortex generator position.

Abstract: Methods for producing ultrasonic sound emissions from wind turbines, active systems for emitting ultrasonic sounds from wind turbines, and wind turbines are provided. In one embodiment, a method includes operating the wind turbine with an ultrasonic sound emitting device mounted on or within a component of the wind turbine, and receiving in a controller at least one indicator. The method further includes determining if an operating condition exists based on the at least one indicator, and supplying a fluid flow through an outlet of the ultrasonic sound emitting device such that an ultrasonic sound emission is produced by the ultrasonic sound emitting device if the operating condition exists.

Abstract: A rotor blade assembly for a wind turbine having a rigid root insert is disclosed. The rotor blade assembly includes a blade root section having an end face with a substantially annular cross-section defined by an outer sidewall surface and an inner sidewall surface. The end face is configured to attach the rotor blade assembly to a hub. The rotor blade assembly includes a radial bore hole provided a predetermined span-wise distance from the end face and extending between the sidewall surfaces and a longitudinal bore hole provided between the sidewall surfaces and extending from the end face to the radial bore hole. The rigid root insert is disposed within the longitudinal bore hole and extends from the end face to the radial bore hole. As such, the rigid root insert is configured to increase the stiffness of the blade root section when the rotor blade assembly is attached to the hub with bolts that extend into and through the radial bore hole and the longitudinal bore hole.