Abstract: A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

Abstract: A method for assembling a shear web assembly of a wind turbine includes providing at least one spar cap. The method also includes forming a spar connecting member of a thermoplastic material via additive manufacturing. Further, the method includes securing the spar connecting member to the spar cap. Moreover, the method includes providing a shear web, forming a web connecting member of a thermoplastic material via additive manufacturing, and securing the web connecting member at a first end of the shear web. In addition, the method includes interconnecting the web connecting member and the spar connecting member at a joint. Thus, the method further includes heating the joint to secure the web connecting member and the spar connecting member together.

Abstract: Methods for manufacturing a wind turbine rotor blade having a flatback airfoil configuration along at least a portion of a span of the rotor blade include providing a shell mold of the rotor blade. The method also includes laying up an outer skin layer of the rotor blade into the shell mold. Further, the method includes placing at least one pre-fabricated corner of the flatback airfoil configuration into the shell mold. The pre-fabricated corner(s) has a pointed edge. The method also includes infusing the outer skin layer with the pre-fabricated corner(s) to form the flatback airfoil configuration.

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: Methods for joining a first blade component and a second blade component of a rotor blade together includes printing and depositing, via a computer numeric control (CNC) device, at least one three-dimensional (3-D) grid structure at a first joint area of the rotor blade. The first joint area contains the first blade component interfacing with the second blade component. The method also includes providing an adhesive at the first joint area to at least partially fill the grid structure. Further, the method includes securing the first blade component and the second blade component together at the first joint area via the adhesive.

Abstract: A method for assembling a shear web assembly of a wind turbine includes providing at least one spar cap. The method also includes forming a spar connecting member of a thermoplastic material via additive manufacturing. Further, the method includes securing the spar connecting member to the spar cap. Moreover, the method includes providing a shear web, forming a web connecting member of a thermoplastic material via additive manufacturing, and securing the web connecting member at a first end of the shear web. In addition, the method includes interconnecting the web connecting member and the spar connecting member at a joint. Thus, the method further includes heating the joint to secure the web connecting member and the spar connecting member together.

Abstract: A method for manufacturing a rotor blade component of a rotor blade includes feeding a flat sheet of material into a thermoforming system, wherein the material comprises at least one of a thermoplastic or thermoset material. The method also includes heating the flat sheet of material via the thermoforming system. Further, the method includes shaping the heated flat sheet of material via at least one roller of the thermoforming system into a desired curved shape. Moreover, the method includes dispensing the shaped sheet of material from the thermoforming system. In addition, the method includes cooling the shaped sheet of material to form the rotor blade component.

Abstract: Methods for manufacturing a wind turbine rotor blade having a flatback airfoil configuration along at least a portion of a span of the rotor blade include providing a shell mold of the rotor blade. The method also includes laying up an outer skin layer of the rotor blade into the shell mold. Further, the method includes placing at least one pre-fabricated corner of the flatback airfoil configuration into the shell mold. The pre-fabricated corner(s) has a pointed edge. The method also includes infusing the outer skin layer with the pre-fabricated corner(s) to form the flatback airfoil configuration.

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 blade for a wind turbine includes a body adapted for movement in response to wind flow past the blade body. The body has an inner surface defining an interior chamber and an opposite outer surface. At least one damping element extends from the inner surface of the body. The at least one damping element is configured to facilitate reducing an amount of noise generated by and propagating through the blade.

Abstract: A wind turbine blade having two shell portions bonded together to form a wind turbine blade having an interior space having an axial length. A web disposed between the shell portions in the interior space and extending substantially the axial length thereof. Lightning receptors are disposed on the shell portions and a conductor is disposed in the interior space. The conductor is configured to contact the lightning receptors. One shell portion of the two shell portions has a removable section, e.g. a plug, receptor or panel, to provide access to the opposite conductor. A cable mounted on the web is configured to extend substantially the axial length of the wind turbine blade and is in electrical contact with the conductor.

Abstract: A spar for a wind turbine blade includes at least one shear web extending between pressure and suction sides of the blade; and a joint, arranged substantially midway between ends of the shear web, for sizing the shear web. The joint may include a resilient and/or expandable spacer.

Abstract: A method of producing a shear web for a wind turbine blade includes providing a mold generally conforming to a shape of at least a portion of a shear web; and filling the mold with a closed cell structural foam.

Abstract: A method of producing a shear web for a wind turbine blade includes providing a mold generally conforming to a shape of at least a portion of a shear web; and filling the mold with a closed cell structural foam.

Abstract: A blade for a wind turbine includes a body adapted for movement in response to wind flow past the blade body. The body has an inner surface defining an interior chamber and an opposite outer surface. At least one damping element extends from the inner surface of the body. The at least one damping element is configured to facilitate reducing an amount of noise generated by and propagating through the blade.

Abstract: A wind turbine blade having two shell portions bonded together to form a wind turbine blade having an interior space having an axial length. A web disposed between the shell portions in the interior space and extending substantially the axial length thereof. Lightning receptors are disposed on the shell portions and a conductor is disposed in the interior space. The conductor is configured to contact the lightning receptors. One shell portion of the two shell portions has a removable section, e.g. a plug, receptor or panel, to provide access to the opposite conductor. A cable mounted on the web is configured to extend substantially the axial length of the wind turbine blade and is in electrical contact with the conductor.

Abstract: A system and methods of impact avoidance for a load transport system are provided. The method includes coupling an elongated load to a transport vehicle, wherein the load includes a supported portion and a cantilevered portion such that the cantilevered portion exceeds a support dimension of the transport vehicle. The method further includes coupling at least one proximity sensor to the load, determining a distance from either the proximity sensor or the load to an object in the field of view of the sensor, transmitting the signal corresponding to the determined distance to a control unit, comparing the determined distance to a predetermined allowable clearance distance and generating a signal based on the comparison.

Abstract: A multi-section blade for a wind turbine comprising a hub extender connected to a hub of the wind turbine is provided. The blade includes at least one pitchable outboard section. The hub extender can have a pitch bearing located near the interface between the hub and hub extender, or the hub extender and outboard blade section. The hub extender can be configured to pitch or not pitch with the outboard blade sections. An aerodynamic fairing is configured to mount over the hub extender and is configured to not pitch with the outboard blade sections.

Abstract: A spar for a wind turbine blade includes at least one shear web extending between pressure and suction sides of the blade; and a joint, arranged substantially midway between ends of the shear web, for sizing the shear web. The joint may include a resilient and/or expandable spacer.

Abstract: A wind turbine includes a tower supporting a drive train with a rotor, at least one hollow blade extending radially from the rotor; a drain hole arranged in a tip portion of the blade; a baffle, arranged inside the blade and inboard of the drain hole, for impeding a flow of particulate matter to the drain hole; a flexible drain conduit arranged inside the blade for connecting to the drain hole; and a non-flexible drain conduit arranged inside the blade for connecting to the flexible drain conduit, the non-flexible conduit having a plurality of openings for receiving fluid from inside the blade.