Abstract: A system and method for manufacturing a wind turbine blade. The wind turbine blade includes a shell structure defining a leading edge and a trailing edge. The wind turbine blade also includes a longitudinal edge extension arranged to extend at least partially along the leading edge or at least partially along the trailing edge to modify an aerodynamic characteristic of the wind turbine blade. The longitudinal edge extension includes a center section and a peripheral section comprising attachment means, and the shell structure is arranged to engage with the attachment means to secure the longitudinal edge extension.

Abstract: A wind turbine blade including a shell structure defining a leading edge and a trailing edge, and an upwind shell and a downwind shell joined along at least one of the leading edge or the trailing edge. The shell structure includes an assembly of preformed parts processed into a collection of prefabricated laminates. The invention also includes a method of manufacturing a wind turbine blade, the method includes processing a number of preformed parts into a collection of prefabricated laminates and assembling the collection of prefabricated laminates to build a shell structure defining a leading edge and a trailing edge.

Abstract: A method for manufacturing an article includes providing a plurality of flat sheets of fiber-reinforced polymer material. The method also includes forming the plurality of flat sheets of the fiber-reinforced polymer material into a plurality of curved sheets of the fiber-reinforced polymer material. Further, the method includes assembling the plurality of curved sheets of the fiber-reinforced polymer material in a tooling device to form an outer shape of the article. Moreover, the method includes securing each of the plurality of curved sheets of the fiber-reinforced polymer material together to form the article.

Abstract: A method for forming a structural tile for use in a composite panel includes providing a base plate of a compression mold assembly. The method also includes placing a grid structure mold of the compression mold assembly atop the base plate. The grid structure mold defines a cavity having a desired shape for a grid structure. Further, the method includes filling the cavity of the grid structure mold with a plurality of fragments of recycled fiber reinforced polymer material. Moreover, the method includes placing a cover plate of the compression mold assembly atop the grid structure mold to apply pressure to the grid structure mold. The method also includes applying heat to the cover plate to heat the plurality of fragments of recycled fiber reinforced polymer material such that the recycled fiber reinforced polymer material melts within the cavity. In addition, the method includes allowing the melted recycled fiber reinforced polymer material to cure to form the structural tile.

Abstract: A method of build-up welding a powdery or wire-shaped material onto a workpiece, which is preferably a flat substrate, by means of a device which comprises a substantially rod-shaped electrode, the electrode having at least one material feed channel extending in its interior, the device comprising a nozzle surrounding the electrode, the method comprising the following steps: forming the arc as a transferred arc between the electrode and the workpiece or as a free-standing arc between the electrode and the nozzle, flooding the working gas area with a working gas to constrict the arc in the direction of the workpiece, feeding the powdery or wire-shaped material into the constricted arc and moving the device across the workpiece as the powdery or wire-shaped material is being fed into the constricted arc.

Abstract: A wind turbine blade including a shell structure defining a leading edge and a trailing edge, and an upwind shell and a downwind shell joined along at least one of the leading edge or the trailing edge. The shell structure includes an assembly of preformed parts processed into a collection of prefabricated laminates. The invention also includes a method of manufacturing a wind turbine blade, the method includes processing a number of preformed parts into a collection of prefabricated laminates and assembling the collection of prefabricated laminates to build a shell structure defining a leading edge and a trailing edge.

Abstract: A system and method for manufacturing a wind turbine blade. The wind turbine blade includes a shell structure defining a leading edge and a trailing edge. The wind turbine blade also includes a longitudinal edge extension arranged to extend at least partially along the leading edge or at least partially along the trailing edge to modify an aerodynamic characteristic of the wind turbine blade. The longitudinal edge extension includes a center section and a peripheral section comprising attachment means, and the shell structure is arranged to engage with the attachment means to secure the longitudinal edge extension.

Abstract: The present disclosure is directed to a method of forming a root portion of a wind turbine rotor blade. A plurality of alignment pins coupled to an alignment plate is aligned with a first set of a plurality of insert cavities defined by a prefabricated panel. Each alignment pin is positioned within one of a first set of a plurality of installation apertures defined by the alignment plate. The prefabricated panel and the alignment plate are coupled such that each alignment pin is positioned within one of the first set of the plurality of insert cavities. A first adhesive is placed in each of the second set of the plurality of insert cavities. A first set of inserts are placed into a second set of the plurality of insert cavities. The first set of inserts and the alignment plate are coupled, and the first adhesive is cured.

Abstract: A wind turbine blade comprising a fairing with a rigid structural component (12) which forms the majority of the aerodynamic profile and a non-actively controllable elastically deformable trailing edge component (14) mounted on the structural component to complete the aerodynamic profile. The trailing edge component (14) is formed from a material having an elastic modulus in the range of 0.5 to 2.5 GPa such it will elastically buckle when loading on the trailing edge component exceeds a predetermined threshold. The structural component (12) comprises a unidirectional reinforcing layer adjacent to the trailing edge component with at least one layer of unidirectional fibers (26) extending in a substantially spanwise direction.

Abstract: A method of forming a structural connection between a spar cap 14 and an aerodynamic fairing 12. A composite comprising an uncured matrix and a compressible solid is applied between the spar cap and fairing and is then compressed and cured to adhere the fairing to the spar cap. The cured matrix composite has a void volume of at least 20%. The high void volume means that as the fairing is compressed into place and compresses the composite, it has space in which to deform so as not to place undue stress on the fairing and to produce a lightweight connection.

Abstract: A self-supporting wind turbine tower with walls comprising an upper portion (12) and a lower portion (14). Substantially all of the upper portion (12) is formed from a composite plastic. Substantially all of the lower portion (14) is formed from mild steel.

Abstract: A wind turbine blade comprising a fairing with a rigid structural component (12) which forms the majority of the aerodynamic profile and a non-actively controllable elastically deformable trailing edge component (14) mounted on the structural component to complete the aerodynamic profile. The trailing edge component (14) is formed from a material having an elastic modulus in the range of 0.5 to 2.5 GPa such it will elastically buckle when loading on the trailing edge component exceeds a predetermined threshold. The structural component (12) comprises a unidirectional reinforcing layer adjacent to the trailing edge component with at least one layer of unidirectional fibres (26) extending in a substantially spanwise direction.

Abstract: A method of forming a structural connection between a spar cap 14 and an aerodynamic fairing 12 A composite comprising an uncured matrix and a compressible solid is applied between the spar cap and fairing and is then compressed and cured to adhere the fairing to the spar cap. The cured matrix composite has a void volume of at least 20%. The high void volume means that as the fairing is compressed into place and compresses the composite, it has space in which to deform so as not to place undue stress on the fairing and to produce a lightweight connection.

Abstract: A self-supporting wind turbine tower with walls comprising an upper portion (12) and a lower portion (14). Substantially all of the upper portion (12) is formed from a composite plastic. Substantially all of the lower portion (14) is formed from mild steel.