Abstract: An automated in-line feed-through system integrating the delivery, application and infusion of a resin to one or more fiber tows and layup of the one or more infused fiber tows to form a composite structure. The system includes an automated resin delivery, deposition and infusion system configured to deposit the resin on a respective one of the one or more fiber tows and form the infused fiber tows. The system integrates an automated layup system including a compaction roller configured to adhere the one or more infused fiber tows to a substrate. The system further includes a controller configured to control a flow rate of the resin, control the temperature of the resin, the infused fiber tows and the automated layup system, and control tension of the one or more infused fiber tows within the automated layup system. Other aspects of the automated in-line system are also provided.

Abstract: A system for inspecting a wind turbine blade having a pair of shells surrounding a shear web. The system includes a scanning machine for taking images of an interior portion of the shells of the wind turbine blade, a measuring apparatus for taking numerous measurements of a defect imaged within the shells of the wind turbine blade, and a look-up table for ascertaining the theoretical strength of the wind turbine blade.

Abstract: A composite section including a concentric arrangement of inner and outer laminates having an interstice therebetween is provided. Both the inner and outer laminates include a matrix material and a fabric layer. A plurality of tubes having an inner cavity, are situated in the interstice of the inner and outer laminates. A reinforcing material is disposed in the interstice and along the length of the concentric arrangement unoccupied by the plurality of tubes to create a composite section. A plurality of tension members are threaded though the plurality of tubes to provide post tensioning to each of the composite sections. The components are easily transported and assembled to form composite sections to provide cost effective on-site tower formation. Also provided is an apparatus to form the inner and outer laminates and a method of formation of the composite section.

Abstract: A method of assembling a wind turbine blade comprises providing a first blade segment comprising at least two first spar cap segments; providing a second blade segment comprising at least two second spar cap segments; inserting the second blade segment into the first blade segment wherein a spar cap cavity is formed between each set of corresponding first and second spar cap segments; injecting an adhesive into the spar cap cavities to bond the blade segments together, wherein a scarf joint is formed between each set of corresponding first and second spar cap segments.

Abstract: A method of manufacturing a fuel cell stack is provided. The method provides forming an inspectable preassembly of multiple fuel cell assemblies that may be termed a pseudostack. Each fuel cell in the pseudostack has permanent electrical interconnections and sealing connections on only one of the two electrodes, namely an anode layer or a cathode layer. For example, an anode interconnect may be firmly attached to the anode layer by means of a bonding agent and a sealing agent used to seal passages on the anode layer of the fuel cell. Alternatively, seals and permanent electrical connections may be made on the cathode layer of the fuel cell, and not on the anode layer.

Abstract: A rotor blade assembly having an access window and methods for assembling a rotor blade are disclosed. The rotor blade assembly may generally include a first shell component and a second shell component. The first shell component may be secured to the second shell component. Additionally, an access region may be defined in the first shell component and/or the second shell component. The access region may generally be configured such that an access window is defined in the rotor blade assembly. The access window may be configured to provide access to the interior of a portion of the rotor blade assembly.

Abstract: A resin infusion apparatus and system, layup system comprising the same, and methods of using these are provided. The resin infusion apparatus comprises a hollow cylinder having a plurality of pores perforating an arcuate surface thereof. The interior of the cylinder is provided with one or more flow restrictors that assist in controlling the flow out of the pores of the cylinder. Laminates made of prepregs prepared using the apparatus and/or system may thus be essentially free of voids.

Abstract: A rotor blade assembly having an access window and methods for assembling a rotor blade are disclosed. The rotor blade assembly may generally include a first shell component and a second shell component. The first shell component may be secured to the second shell component. Additionally, an access region may be defined in the first shell component and/or the second shell component. The access region may generally be configured such that an access window is defined in the rotor blade assembly. The access window may be configured to provide access to the interior of a portion of the rotor blade assembly.

Abstract: In-line inspection methods are provided. The methods comprise measuring at least two parameters/properties of a prepreg and/or laminate during the manufacture thereof. In some embodiments, the data collected using the inline inspection methods may be processed and/or provided to a manual or automated controller, in order to provide a closed loop method for the manufacture of the prepregs and/or laminates. Apparatus for carrying out the methods are also provided, as are articles comprising a prepreg and/or laminate made using the apparatus.

Abstract: A fluid turbine blade is provided. The fluid turbine blade includes a centrally disposed longitudinal spar having a substantially circumferential cross section. The fluid turbine blade also includes at least one rib assembly affixed to said longitudinal spar. The fluid turbine blade further includes a skin attached to the at least one rib.

Abstract: A turbine blade includes at least two blade segments. Each blade segment includes first and second shells joined together, a base region, at least one joint region including a mating face. Each of the first and second shells includes an outer skin, a base spar cap attached to an inner surface of the outer skin in the base region, a joint spar cap attached to the inner surface of the outer skin in the joint region and adjacent to at least a portion of the base spar cap. The joint spar cap includes holes in the mating face of the joint region. The turbine blade further includes fasteners within the holes for securing the at least two blade segments together.

Abstract: A fuel cell assembly comprises a separating structure configured for separating a first reactant and a second reactant wherein the separating structure has an opening therein. The fuel cell assembly further comprises a fuel cell comprising a first electrode, a second electrode, and an electrolyte interposed between the first and second electrodes, and a passage configured to introduce the second reactant to the second electrode. The electrolyte is bonded to the separating structure with the first electrode being situated within the opening, and the second electrode being situated within the passage.

Abstract: A method of manufacturing a fuel cell stack is provided. The method provides forming an inspectable preassembly of multiple fuel cell assemblies that may be termed a pseudostack. Each fuel cell in the pseudostack has permanent electrical interconnections and sealing connections on only one of the two electrodes, namely an anode layer or a cathode layer. For example, an anode interconnect may be firmly attached to the anode layer by means of a bonding agent and a sealing agent used to seal passages on the anode layer of the fuel cell. Alternatively, seals and permanent electrical connections may be made on the cathode layer of the fuel cell, and not on the anode layer.

Abstract: A wind turbine includes a plurality of wind turbine blades attached to a rotor positioned atop a tower affixed to a tower foundation. At least one blade pitch sensor is configured to measure blade pitch angles for one or more of the wind turbine blades. A rotor/generator speed sensor is configured to measure the rotational speed of the wind turbine rotor, a corresponding wind turbine generator, or both. A wind turbine nacelle yaw sensor is configured to measure the nacelle yaw, while at least two tower-base bending sensors are configured without use of adhesives, cements or bonding agents to provide large-area measurement of tower deflection. A controller is configured to adjust the pitch angle of one or more of the wind turbine blades in response to the measured one or more blade pitch angles, the measured rotational speed, the measured nacelle yaw and measured tower longitudinal deflection.

Abstract: A planar fuel cell stack is provided. The planar fuel cell stack comprises an anode interconnect structure comprising a corrugated first internal manifold connected to a first anode flowfield; a cathode interconnect structure comprising a corrugated second internal manifold connected to a first cathode flowfield; and a thermally active, surface insulated metallic seal disposed between the corrugated parts of the anode and cathode interconnects, such that the thermally active metallic seal responds upon the application of heat to provide sealing between the anode interconnect structure and the cathode interconnect structure.

Abstract: A multi-segment wind turbine blade comprises at least two blade segments. A first spar cap segment is attached to a first blade segment and a second spar cap segment is attached to a second blade segment. The first and second spar cap segments are configured to form a scarf joint. First and second spar cap brackets are attached in locations of the first and second spar cap segments, respectively, selected to facilitate alignment of the first and second spar cap segments at the scarf joint. At a field site, the first and second spar cap segments are bonded after fastening the first and second spar cap brackets.

Abstract: A turbine blade includes at least two blade segments. Each blade segment includes first and second shells joined together, a base region, at least one joint region including a mating face. Each of the first and second shells includes an outer skin, a base spar cap attached to an inner surface of the outer skin in the base region, a joint spar cap attached to the inner surface of the outer skin in the joint region and adjacent to at least a portion of the base spar cap. The joint spar cap includes holes in the mating face of the joint region. The turbine blade further includes fasteners within the holes for securing the at least two blade segments together.

Abstract: A wind turbine includes a plurality of wind turbine blades attached to a rotor positioned atop a tower affixed to a tower foundation. At least one blade pitch sensor is configured to measure blade pitch angles for one or more of the wind turbine blades. A rotor/generator speed sensor is configured to measure the rotational speed of the wind turbine rotor, a corresponding wind turbine generator, or both. A wind turbine nacelle yaw sensor is configured to measure the nacelle yaw, while at least two tower-base bending sensors are configured without use of adhesives, cements or bonding agents to provide large-area measurement of tower deflection. A controller is configured to adjust the pitch angle of one or more of the wind turbine blades in response to the measured one or more blade pitch angles, the measured rotational speed, the measured nacelle yaw and measured tower longitudinal deflection.

Abstract: The invention provides composite systems, articles comprising the composite system, methods for the in-situ, non-destructive testing of the articles and/or composite systems, as well as array probes useful in the methods. The composite systems comprise a curable resin and at least one plurality of detectable particles.

Abstract: A method of assembling a wind turbine blade comprises providing a first blade segment comprising at least two first spar cap segments; providing a second blade segment comprising at least two second spar cap segments; inserting the second blade segment into the first blade segment wherein a spar cap cavity is formed between each set of corresponding first and second spar cap segments; injecting an adhesive into the spar cap cavities to bond the blade segments together, wherein a scarf joint is formed between each set of corresponding first and second spar cap segments.