Patents by Inventor Paul Badger

Paul Badger has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 11933275
    Abstract: A wind turbine blade comprising an electro-thermal heating element with a tapering width. The electro-thermal heating element comprises: electrically resistive sheet material; a first electrode which is in electrical contact with the sheet material and positioned at a first end of the element; and a second electrode which is in electrical contact with the sheet material and positioned at a second end of the sheet material. An electrically conductive strip extends across a width of the element. The sheet material has a first part on a first side of the strip and a second part on a second side of the strip. The strip is in electrical contact with the first and second parts of the sheet material. The first part of the sheet material has a first width, and the second part of the sheet material has a second width which is different to the first width.
    Type: Grant
    Filed: August 4, 2020
    Date of Patent: March 19, 2024
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Luke Spandley, Paul Badger
  • Patent number: 11920557
    Abstract: A first aspect of the invention provides a wind turbine blade having a blade shell that defines a suction side, pressure side, leading edge, and a trailing edge of the blade. The blade further comprises a blade heating system comprising one or more heating elements configured to heat the blade in first and second heating areas, wherein the first heating area is closer to the leading edge than the second heating area is, and the heating system is configured to generate heat fluxes in the first and second heating areas such that the heat flux generated in the first heating area is lower than the heat flux generated in the second heating area.
    Type: Grant
    Filed: August 4, 2020
    Date of Patent: March 5, 2024
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Luke Spandley, Paul Badger
  • Patent number: 11905933
    Abstract: The present invention relates to a method and controller for heating a wind turbine blade that comprises a plurality of heating zones. An icing factor is determined based on environmental conditions and one or more heating zones are determined based on the determined icing factor, wherein each heating zone comprises one or more Electro-Thermal Heating Elements. The one or more Electro-Thermal Heating Elements corresponding to the determined heating zones are activated to generate heat.
    Type: Grant
    Filed: December 22, 2016
    Date of Patent: February 20, 2024
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Stephen Buggy, Luke Spandley, Paul Badger
  • Patent number: 11570850
    Abstract: The present invention relates to methods and electro-thermal heating elements in which the electro-thermal heating element comprises a cut-out. Forming at least one multi-resistance patch for the cut-out and attaching the at least one multi-resistance patch to the electro-thermal heating element proximate to the cut-out.
    Type: Grant
    Filed: June 15, 2018
    Date of Patent: January 31, 2023
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Luke Spandley, Paul Badger
  • Patent number: 11542922
    Abstract: The present invention relates to a method of controlling an electro-thermal heating system in a wind turbine blade, comprising measuring a supply voltage to the electro-thermal heating system, determining a duration of a variable time based enforced off period based on the measured supply voltage, and inserting the variable time based enforced off period between subsequent switching duty cycles that controls the electro-thermal heating system. The present invention also relates to a wind turbine that comprises one or more wind turbine blades wherein each wind turbine blade comprises an electro-thermal heating system and a processor adapted to perform the method.
    Type: Grant
    Filed: June 21, 2018
    Date of Patent: January 3, 2023
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Arran Wood, Stephen Buggy, Paul Badger
  • Publication number: 20220403823
    Abstract: There is provided a method of avoiding edgewise vibrations during a non-operational period of a wind turbine. The method comprises defining a non-operational period for a wind turbine arranged at a specific site, determining expected wind conditions at the specific site during the non-operational period and defining a plurality of potential yaw orientations for the wind turbine. The method further comprises determining the relative probability of edgewise vibrations occurring during the non-operational period for each potential yaw orientation based upon the expected wind conditions during the non-operational period, determining one or more preferred yaw orientations, which are the yaw orientations in which the probability of edgewise vibrations occurring is lowest, and arranging the wind turbine in one of the preferred yaw orientations during the non-operational period.
    Type: Application
    Filed: November 25, 2020
    Publication date: December 22, 2022
    Inventors: Benjamin Rowlinson, Paul Badger, Tomas Vronsky
  • Patent number: 11519382
    Abstract: A wind turbine blade (2) comprising an outer shell (6) incorporating a metallic foil component (20), a conductive blade component (12) in-board of the metallic foil component (20), and a fabric sheet assembly (22) positioned between the metallic component (20) and the conductive blade component (12). The fabric sheet assembly comprises: one or more non-conductive fabric sheets (28, 30) which define first and second outer surfaces (24, 26) of the fabric sheet assembly (22); and at least one conductive thread stitch (34) penetrating a depth of the one or more fabric sheets (28, 30) and being exposed at the outer surfaces (24, 26); thereby to enable equipotential bonding between the conductive blade component (12) and the metallic foil component (20).
    Type: Grant
    Filed: October 1, 2018
    Date of Patent: December 6, 2022
    Assignee: Vestas Wind Systems A/S
    Inventors: Paul Badger, Luke Spandley
  • Publication number: 20220349389
    Abstract: A wind turbine blade comprising an electro-thermal heating element with a tapering width. The electro-thermal heating element comprises: electrically resistive sheet material; a first electrode which is in electrical contact with the sheet material and positioned at a first end of the element; and a second electrode which is in electrical contact with the sheet material and positioned at a second end of the sheet material. An electrically conductive strip extends across a width of the element. The sheet material has a first part on a first side of the strip and a second part on a second side of the strip. The strip is in electrical contact with the first and second parts of the sheet material. The first part of the sheet material has a first width, and the second part of the sheet material has a second width which is different to the first width.
    Type: Application
    Filed: August 4, 2020
    Publication date: November 3, 2022
    Inventors: Luke SPANDLEY, Paul BADGER
  • Publication number: 20220349387
    Abstract: A first aspect of the invention provides a wind turbine blade comprising an electro-thermal heating element, the electro-thermal heating element comprising a sheet of electrically resistive material which is folded so as to provide a plurality of heat zones, each heat zone comprising one or more layers of the sheet, wherein at least two of the heat zones have a different number of layers of the sheet.
    Type: Application
    Filed: August 4, 2020
    Publication date: November 3, 2022
    Inventors: Paul BADGER, Luke SPANDLEY
  • Publication number: 20220282698
    Abstract: A first aspect of the invention provides a wind turbine blade having a blade shell that defines a suction side, pressure side, leading edge, and a trailing edge of the blade. The blade further comprises a blade heating system comprising one or more heating elements configured to heat the blade in first and second heating areas, wherein the first heating area is closer to the leading edge than the second heating area is, and the heating system is configured to generate heat fluxes in the first and second heating areas such that the heat flux generated in the first heating area is lower than the heat flux generated in the second heating area.
    Type: Application
    Filed: August 4, 2020
    Publication date: September 8, 2022
    Inventors: Luke SPANDLEY, Paul BADGER
  • Publication number: 20220243703
    Abstract: A method of inspecting a wind turbine blade. The wind turbine blade comprises an electro-thermal heating element and a surface protection layer. The method comprises: exposing a test point of the electro-thermal heating element; contacting the test point to establish an electrical connection between the test point and a sensor; and electrically connecting the sensor to the surface protection layer. The sensor is operated to measure a resistance value indicative of an electrical resistance between the test point and the surface protection layer. The resistance value is analysed to determine a condition of the wind turbine blade. The invention provides a method of inspecting a wind turbine blade which enables damage or defects to be detected which may be difficult to detect by visual inspection or traditional non-destructive testing techniques. For instance, the resistance value may give an indication of the presence of an electrical short between the heating element and the surface protection layer.
    Type: Application
    Filed: July 27, 2020
    Publication date: August 4, 2022
    Inventors: Luke Spandley, Darren Rogers, Arran Wood, Paul Badger
  • Patent number: 11319934
    Abstract: Examples of the present disclosure generally relate to wind turbine blades configured to minimize or eliminate buildup of ice on the blades. In order to maintain an ice free surface on a wind turbine blade, one or more ETH panels are embedded in the wind turbine blade to heat the wind turbine blade. One or more busbars are electrically connected to each of the one or more ETH panels for conducting electrical power to the ETH panels. The busbars may be disposed in an overlapping configuration to provide uniform heating of the wind turbine blade.
    Type: Grant
    Filed: June 29, 2017
    Date of Patent: May 3, 2022
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Luke Spandley, Paul Badger, Stephen Buggy
  • Patent number: 11225947
    Abstract: A method of securing a cable (22) to a wind turbine blade is described. The method involves providing a pre-assembled cable assembly (34) comprising a cable (22) and a plurality of mounts (40a-e) pre-attached to the cable (22) at intervals along the length of the cable (22). The plurality of mounts (40a-e) is attached to a surface (20) of a wind turbine blade such that the mounts (40a-e) are spaced apart along the surface (20) of the blade. The spacing between adjacent mounts (40a-e) when the mounts (40a-e) are attached to the blade is less than the length of the cable (22) between said adjacent mounts (40a-e) such that a predetermined amount of slack is provided in the cable (22) between said adjacent mounts (40a-e). A pre-assembled cable assembly for use in the method is also described together with a method of assembling the cable assembly.
    Type: Grant
    Filed: June 12, 2017
    Date of Patent: January 18, 2022
    Assignee: Vestas Wind Systems A/S
    Inventors: Luke Spandley, Paul Badger, Stephen Buggy
  • Publication number: 20210404443
    Abstract: A wind turbine rotor blade spar cap includes a stack of layers of conductive material. An intermediate layer is bonded between adjacent layers of the conductive material. The intermediate layer includes a portion of conductive material which is electrically coupled to the adjacent layers of conductive material so as to equipotentially bond the adjacent layers of the conductive material via the intermediate layer.
    Type: Application
    Filed: November 15, 2019
    Publication date: December 30, 2021
    Inventors: Angela Thwaites, Paul Badger
  • Patent number: 11187203
    Abstract: A wind turbine blade includes a plurality of layered sections coupled together end-to-end. Each section includes a side wall that forms a tubular structure and includes at least one bore. When the sections are coupled together, the bores generally align to form a conduit. A strengthening element extends through the conduit and is configured to reinforce the blade under load during use of the wind turbine. A wind turbine includes a tower, a nacelle, and a rotor including a hub and at least one wind turbine blade including a plurality of layered sections extending from the hub. A method of forming a wind turbine blade through an additive manufacturing process is also disclosed.
    Type: Grant
    Filed: November 30, 2016
    Date of Patent: November 30, 2021
    Assignee: Vestas Wind Systems A/S
    Inventor: Paul Badger
  • Patent number: 11168670
    Abstract: The present invention relates to a method, controller, wind turbine and wind farm that advantageously determines an ice throw risk zone (302) for a wind turbine (301), wherein the ice throw risk zone (302) defines an area surrounding the wind turbine (301) within which ice can be thrown from one or more blades of the wind turbine (301); determining whether the determined ice throw risk zone (302) impinges one or more exclusion zones; and if the determined ice throw risk zone (302) impinges one or more exclusion zones, determining an alteration to one or more operating parameters of the wind turbine (301) in order to alter the ice throw risk zone (302) such that the determined ice throw risk zone (302) does not impinge the one or more exclusion zones.
    Type: Grant
    Filed: December 13, 2017
    Date of Patent: November 9, 2021
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Paul Badger, Brian Daugbjerg Nielsen, Peter Tranum Thomsen
  • Patent number: 11118573
    Abstract: A method of repairing erosion on a wind turbine blade while on a wind turbine includes placing a scanning device on an erosion zone. The device scans the erosion zone to gather an image and/or digital data. A printing system deposits a material according to the image and/or digital data. The repair system may include a frame such that scanning and/or depositing are with respect to the frame. A processing system interprets the image and/or digital data and produces an instruction file. Depositing the material may include depositing the material according to the instruction file. An unmanned aerial vehicle may be operated to position at least one of the scanning device and the printing system on the wind turbine blade. Alternatively, a rope/wire system may be operated to lower at least one of the scanning device and the printing system along the wind turbine blade.
    Type: Grant
    Filed: December 12, 2017
    Date of Patent: September 14, 2021
    Assignee: Vestas Wind Systems A/S
    Inventors: Paul Badger, Servet Sert
  • Publication number: 20210148338
    Abstract: The present invention relates to a method of controlling an electro-thermal heating system in a wind turbine blade, comprising measuring a supply voltage to the electro-thermal heating system, determining a duration of a variable time based enforced off period based on the measured supply voltage, and inserting the variable time based enforced off period between subsequent switching duty cycles that controls the electro-thermal heating system. The present invention also relates to a wind turbine that comprises one or more wind turbine blades wherein each wind turbine blade comprises an electro-thermal heating system and a processor adapted to perform the method.
    Type: Application
    Filed: June 21, 2018
    Publication date: May 20, 2021
    Inventors: Arran WOOD, Stephen BUGGY, Paul BADGER
  • Publication number: 20210153301
    Abstract: The present invention relates to methods and electro-thermal heating elements in which the electro-thermal heating element comprises a cut-out. Forming at least one multi-resistance patch for the cut-out and attaching the at least one multi-resistance patch to the electro-thermal heating element proximate to the cut-out.
    Type: Application
    Filed: June 15, 2018
    Publication date: May 20, 2021
    Inventors: Luke SPANDLEY, Paul BADGER
  • Patent number: 10927821
    Abstract: Examples are generally directed to techniques for controlling a temperature of a blade in a wind turbine system. One example of the present disclosure is a method of controlling a temperature of a blade in a wind turbine system. The method includes setting a target temperature, inputting physical conditions of the blade and ambient conditions about the blade into a processor, outputting a minimum amount of energy to a heating element of the blade required to reach the target temperature based on the physical conditions and ambient conditions, and adjusting the energy provided to the heating element to reach the target temperature.
    Type: Grant
    Filed: March 30, 2017
    Date of Patent: February 23, 2021
    Assignee: VESTAS WIND SYSTEMS A/S
    Inventors: Paul Badger, Luke Spandley, Stephen Buggy, Karl Gregory