Abstract: The present disclosure is directed methods for modifying molds of rotor blades of a wind turbine. In certain embodiments, the blade mold is constructed, at least in part, of a thermoplastic material optionally reinforced with a fiber material. In one embodiment, the method includes identifying at least one blade mold addition for the mold of the rotor blade and positioning the blade mold addition at a predetermined location of the mold of the rotor blade. Further, the blade mold addition is constructed, at least in part, of a thermoplastic material. Thus, the method includes applying at least one of heat, pressure, or one or more chemicals at an interface of the blade mold addition and the mold so as to join the blade mold addition to the mold. In further embodiments, the methods described herein are also directed repairing thermoplastic blade molds.

Abstract: The present disclosure is directed to a rotor blade assembly for a wind turbine. The rotor blade assembly includes a rotor blade having surfaces defining a pressure side, a suction side, a leading edge, and a trailing edge extending between a blade tip and a blade root. Further, the rotor blade assembly includes a flexible extension having a first end and a second end. More specifically, the first end is mounted to a surface of the rotor blade and the second end is free. As such, during operation of the wind turbine, the flexible extension passively adjusts with a changing angle of attack of the rotor blade, thereby reducing variations in blade loading.

Abstract: The present disclosure is directed to a method of assembling a modular rotor blade of a wind turbine. The method includes identifying a main blade structure, constructed at least in part, from at least one of a thermoset or a thermoplastic material. The method also includes identifying at least one blade segment, constructed at least in part, of a thermoplastic material reinforced with at least one of glass fibers or carbon fibers. Thus, the method also includes securing the at least one blade segment to the main blade structure, e.g. via welding.

Abstract: A root assembly for a rotor blade of a wind turbine 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 shear web for a rotor blade of a wind turbine and a method of manufacturing and assembling same. The rotor blade generally includes an upper shell member having an upper spar cap configured on an internal surface thereof and a lower shell member having a lower spar cap configured on an internal surface thereof. Further, the shear web extends between the spar caps along a longitudinal length of the blade. In addition, the shear web includes first and second outer pultruded layers at least partially encompassing a core material, wherein end portions of the first and second outer pultruded layers form compressed flanges at opposing ends of the shear web.

Abstract: The present disclosure is directed to methods for joining rotor blade components using thermoplastic welding.

Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame or tray of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.

Abstract: The present disclosure is directed methods for manufacturing spar caps for wind turbine rotor blades. In certain embodiments, the method includes forming an outer frame of the spar cap via at least one of three-dimensional (3D) pultrusion, thermoforming, or 3D printing. As such, the outer frame has a varying cross-section that corresponds to a varying cross-section of the rotor blade along a span thereof. The method also includes arranging a plurality of structural materials (e.g. layers of pultruded plates) within the pultruded outer frame of the spar cap and infusing the structural materials and the outer frame together via a resin material so as to form the spar cap. The resulting spar cap can then be easily incorporated into conventional rotor blade manufacturing processes and/or welded or bonded to an existing rotor blade.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof, e.g. using 3D printing. In one embodiment, the method includes forming a rotor blade structure having a first surface and an opposing, second surface, the first and second surfaces being substantially flat. Another step includes printing a leading edge segment of the rotor blade onto the first surface, wherein heat from the printing bonds the leading edge segment to the first surface. The method also includes rotating the rotor blade structure having the leading edge segment attached thereto. A further step includes printing a trailing edge segment of the rotor blade onto the second surface, wherein heat from the printing bonds the trailing edge segment to the second surface. Another step includes securing one or more fiber-reinforced outer skins to the leading and trailing edge segments so as to complete the rotor blade.

Abstract: The present disclosure is directed to methods for manufacturing wind turbine rotor blades and components thereof. In one embodiment, the method includes forming an outer surface of a rotor blade panel from one or more fiber-reinforced outer skins. The method also includes printing and depositing at least one reinforcement structure onto an inner surface of the one or more fiber-reinforced outer skins to form the rotor blade panel, wherein the reinforcement structure bonds to the one or more fiber-reinforced outer skins as the reinforcement structure is being deposited.

Abstract: The present disclosure is directed methods for modifying molds of rotor blades of a wind turbine. In certain embodiments, the blade mold is constructed, at least in part, of a thermoplastic material optionally reinforced with a fiber material. In one embodiment, the method includes identifying at least one blade mold addition for the mold of the rotor blade and positioning the blade mold addition at a predetermined location of the mold of the rotor blade. Further, the blade mold addition is constructed, at least in part, of a thermoplastic material. Thus, the method includes applying at least one of heat, pressure, or one or more chemicals at an interface of the blade mold addition and the mold so as to join the blade mold addition to the mold. In further embodiments, the methods described herein are also directed repairing thermoplastic blade molds.

Abstract: The present disclosure is directed to tip extensions for wind turbine rotor blades and methods of installing same. The method includes removing a removable blade tip of a lightning protection system from the rotor blade so as to expose a down conductor of the lightning protection system. The method also includes securing a conductive extension to the down conductor. Moreover, the method includes sliding the first end of the tip extension over the conductive extension so as to overlap the rotor blade at the tip end. In addition, the method includes securing the removable blade tip to the conductive extension at the second end of the tip extension. Further, the method includes securing the tip extension to the rotor 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 methods for attaching a plurality of surface features to a rotor blade of a wind turbine. Such methods may include direct molding of the surface features to the rotor blade, bonding arrays of connected components to the rotor blade and subsequently removing connections between components, as well as using a flexible template with or without a tinted adhesive.

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 heating first and second sheets of thermoplastic material to a forming temperature; placing the first sheet of thermoplastic material within a first half of a thermoforming mold and the second sheet of thermoplastic material in an opposite, second half of the thermoforming mold; forming the first sheet of thermoplastic material to the first half of the thermoforming mold; forming the second sheet of thermoplastic material to the second half of the thermoforming mold; compressing the first and second halves of the thermoforming mold so as to join at least a portion of the first and second sheets together; and, releasing the joined first and second sheets of thermoplastic material from the thermoforming mold so as to form the rotor blade component.

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 vortex generator configured for mounting to either of a suction side or a pressure side of a rotor blade. The vortex generator includes a base portion having a contour in an uninstalled state that substantially aligns with or conforms to a contour of a plurality of locations of either on the suction side or the pressure side of the rotor blade. Further, the vortex generator includes a protrusion member extending upwardly from the base portion. The protrusion member includes a plurality of tines separated by at least one slit. Moreover, the base portion and the protrusion member are constructed of a rigid material. In addition, the vortex generator includes a flexible coating material configured at least partially around the base portion and/or within or around the at least one slit.

Abstract: A method for installing an add-on component onto a tip of a wind turbine blade, the associated blade, and the component, are provided. The add-on component has a span-wise end and a separated trailing edge, and is slidable onto the blade tip. Strips of a double-sided adhesive tape are attached onto either or both pressure and suction side surfaces of the blade adjacent the blade tip, or onto interior surfaces of the add-on component, the tape strips having a release liner on an opposite exposed side thereof. An extension tail is configured with the release liner that extends beyond the span-wise end of the add-on component when the add-on component is placed and held at a desired position on the blade. The add-on component is slid onto and maintained in position on the blade tip and, starting from the tape strip furthest from the separated trailing edge, extension tails of the respective tape strips are sequentially peeled through the separated trailing edge and away from the add-on component.

Abstract: A method for installing an add-on component to a surface of a wind turbine blade includes attaching an adhesive side of strips of a double-sided adhesive tape onto either the surface of the wind turbine blade or a surface of the add-on component, the tape strips having a release liner on an opposite exposed side thereof. The tape strips having an extension tail of the release liner that extends beyond an edge of the add-on component when the add-on component is placed and held at a desired position against the surface of the wind turbine blade. With the add-on component held at the desired position, the extension tail is pulled away at an angle such that that release liner is removed along the length of the tape strip while maintaining the add-on component against the blade surface to attach the exposed adhesive under the release liner to either the surface of the wind turbine blade or the surface of the add-on component.

Abstract: A method is provided for installing an add-on component to a surface of a wind turbine blade, as well as the blade with attached add-on component, and the add-on component as a stand-alone device. A slot is defined in one or both of the pressure side or suction side surfaces of the add-on component. The adhesive side of strips of a double-sided adhesive tape are attached onto either the surface of the wind turbine blade or an interior surface of the add-on component, the tape strips having a release liner on an opposite exposed side thereof. The tape strips are arranged longitudinally along one or both sides of the slot, and each strip has an extension tail that extends beyond an edge of the add-on component when component is held at a desired position against the surface of the wind turbine blade.