Wind turbine blade spar structure and method of assembling wind turbine blade using same

Abstract

A method of assembling a wind turbine blade includes providing a load-bearing spar structure having one or more positioning features for positioning one or more wind turbine blade segments, the load-bearing spar structure secured to a securing device, the securing device being movable and extendable. The method further includes at least one of moving and extending the fixture to at least one of move and lift the load-bearing spar structure through the assembly line. The method further includes positioning one or more wind turbine blade segments onto one or more positioning features of the load-bearing spar structure when the fixture is at least one of moved and extended through the assembly line. The method further includes securing one or more wind turbine blade segments to the load-bearing spar structure.

Description

Technical Field

[0001] The present disclosure relates generally to wind turbines, and more particularly to spar structures and methods of assembling wind turbine blades using the spar structures. Background Art

[0002] Wind power is considered to be one of the cleanest and most environmentally friendly energy sources currently available, and wind turbines have received increasing attention in this regard. Modern wind turbines typically include a tower, a generator, a gearbox, a nacelle, and a rotor with a rotatable hub, which carries one or more wind turbine blades. Wind turbine blades capture the kinetic energy of the wind using the known airfoil principle. The wind turbine blades transmit kinetic energy in the form of rotational energy to rotate the shaft, which connects the wind turbine blades to the gearbox, or directly to the generator if a gearbox is not used. The generator then converts the mechanical energy into electrical energy that can be deployed to the utility grid. Therefore, the amount of electrical energy that can be deployed to the grid depends on the amount of mechanical energy that the wind turbine can capture. For this reason, the size of wind turbine blades continues to increase, and therefore the weight continues to increase, to capture more mechanical energy.

[0003] Wind turbine blades generally include a suction side shell and a pressure side shell, typically formed by a molding process, joined together at a join line at the leading and trailing edges of the blade. The main body shell is typically reinforced with one or more structural members (e.g., opposing spar caps with a shear web disposed therebetween) that engage the inner pressure and suction side surfaces of the shell halves. Many wind turbine blades also typically include a leading edge join cap located at the leading edge of the wind turbine blade between the suction side shell and the pressure side shell.

[0004] The spar caps are typically made of a variety of materials, including but not limited to glass fiber laminate composites and / or carbon fiber laminate composites. The shell of a wind turbine blade is generally built around the spar caps of the blade by stacking layers of fiber fabric in a shell mold. These layers are then typically infused with resin.

[0005] As wind turbine blades continue to increase in size, conventional infusion processes face challenges in the production of larger blades (e.g., wind turbine blades exceeding 90 meters). These challenges may include, for example, infusion quality issues and longer maintenance time.

[0006] Thus, modern methods of manufacturing wind turbine blades may include forming the wind turbine blades into segments. The blade segments may then be assembled to form the wind turbine blade. For example, some modern wind turbine blades have a modular panel configuration, such as those described in U.S. Patent Application No. 14 / 753,137, filed on June 29, 2015 and entitled “Modular Wind Turbine Blades and Methods of Assembling Them,” which is incorporated herein by reference in its entirety.

[0007] In view of the foregoing, the art is continually seeking new and improved methods of assembling wind turbine blades. Summary of the invention

[0008] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0009] In one aspect, the present disclosure relates to a method for assembling a wind turbine blade. The method includes providing a load-bearing spar structure having one or more locating features for locating one or more wind turbine blade segments, the load-bearing spar structure being fixed to a fixture, the fixture being movable and extendable. The method also includes at least one of moving and extending the fixture so as to at least one of move and lift the load-bearing spar structure to pass through an assembly line. The method also includes positioning one or more wind turbine blade segments on the one or more locating features of the load-bearing spar structure while at least one of move and extend the fixture to pass through the assembly line. The method also includes fixing the one or more wind turbine blade segments to the load-bearing spar structure.

[0010] In an embodiment, at least one of the movement or extension of the fixing device is achieved via a conveying device.

[0011] In a further embodiment, the conveyor operates continuously through an assembly line to assemble wind turbine blades.

[0012] In additional embodiments, a conveyor is pulsed through an assembly line to assemble wind turbine blades.

[0013] In other embodiments, the assembly line includes a plurality of stations, each station including a different subset of one or more wind turbine blade segments for positioning on the load-bearing spar structure. In addition, in embodiments, the method also includes assembling the subset of one or more wind turbine blade segments on the load-bearing spar structure at the plurality of stations and securing the subset of one or more wind turbine blades to the spar structure at the plurality of stations.

[0014] In yet further embodiments, the method further comprises supplying a subset of the one or more wind turbine blade segments into the assembly line via one or more supply lines.

[0015] In other additional embodiments, the first subset of one or more wind turbine blade segments at the first station of the assembly line includes at least a blade root segment. Furthermore, in an embodiment, the method further comprises positioning the blade root segment onto the load-bearing spar structure at the first station.

[0016] In further additional embodiments, the one or more intermediate subsets of the one or more wind turbine blade segments at the one or more intermediate stations of the assembly line include at least one of a leading edge segment, a trailing edge segment, a pressure side segment, or a suction side segment. Furthermore, in embodiments, the method further comprises positioning the one or more intermediate subsets of the one or more wind turbine blade segments on the load-bearing spar structure at the one or more intermediate stations.

[0017] In yet other embodiments, an additional subset of one or more wind turbine blade segments at a terminal station of the assembly line includes at least a blade tip segment. Furthermore, in an embodiment, the method further comprises positioning the blade tip segment onto the load-bearing spar structure at the terminal station.

[0018] In yet other embodiments, an additional subset of one or more wind turbine blade segments at a terminal station of the assembly line comprises one or more aerodynamic blade features.Furthermore, in an embodiment, the method further comprises positioning the one or more aerodynamic blade features onto the load-bearing spar structure at the terminal station.

[0019] In other embodiments, the one or more aerodynamic blade features include at least one of a vortex generator, a fairing, or a flow fence.

[0020] In yet other embodiments, securing the one or more wind turbine blade segments to the load-bearing spar structure further comprises bonding the one or more wind turbine blade segments to the load-bearing spar structure via one or more adhesives at a terminal station of the assembly line.

[0021] In yet other embodiments, positioning the one or more wind turbine blade segments on the one or more locating features of the load-bearing spar structure further comprises positioning one or more of the one or more wind turbine blade segments on the one or more locating features of the load-bearing spar structure using a crane.

[0022] In yet other embodiments, the one or more locating features include at least one of a groove, a protrusion, a depression, a mark, an indentation, or a combination thereof.

[0023] In other embodiments, the load-bearing spar structure includes a first spar cap, a second spar cap, and a shear web disposed between the first and second spar caps.

[0024] In a further embodiment, at least one of the one or more locating features is located on the shear web.

[0025] In another aspect, the present disclosure relates to a kit for assembling a wind turbine blade. The kit includes a load-bearing spar structure, the load-bearing spar structure including one or more locating features. The kit also includes a fixture supporting the load-bearing spar structure, the fixture being movable along at least one axis and extending around at least one axis. The kit also includes an assembly line, the assembly line including a plurality of stations arranged along at least one axis and a conveyor fixed to the fixture, the conveyor being used to move the fixture along at least one axis to each of the plurality of stations. The kit also includes one or more wind turbine blade segments, which can be attached to the one or more locating features of the load-bearing spar structure, the one or more wind turbine blade segments including one or more subsets of wind turbine blade segments, at least one of the subsets of wind turbine blade segments being placed at each of the plurality of stations. The kit also includes a predetermined mapping for placing the one or more wind turbine blade segments on the load-bearing spar structure, the predetermined mapping defining a position for each of the one or more wind turbine blade segments on the one or more locating features of the load-bearing spar structure.

[0026] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] A complete and enabling disclosure of the invention, including the best mode thereof, to one of ordinary skill in the art is set forth in the specification, which refers to the accompanying drawings, in which:

[0028] Figure 1 shows a perspective view of an embodiment of a wind turbine according to the present disclosure;

[0029] Figure 2 A perspective view showing an embodiment of a wind turbine blade of a wind turbine according to the present disclosure;

[0030] Figure 3 Shows Figure 2 An exploded view of a modular wind turbine blade;

[0031] Figure 4 shows a cross-sectional view of an embodiment of a leading edge segment of a modular wind turbine blade according to the present disclosure;

[0032] Figure 5 shows a cross-sectional view of an embodiment of a trailing edge segment of a modular wind turbine blade according to the present disclosure;

[0033] Figure 6 It shows that according to the present disclosure Figure 2 A cross-sectional view of a modular wind turbine blade;

[0034] Figure 7 It shows that according to the present disclosure Figure 2 A cross-sectional view of a modular wind turbine blade;

[0035] Figure 8 A flow chart showing an embodiment of a method of joining wind turbine blade components according to the present disclosure;

[0036] Fig. 9 shows a cross-sectional view of an embodiment of a spar structure of a wind turbine blade according to the present disclosure;

[0037] Figures 10A-10E Various embodiments of locating features of a spar structure according to the present disclosure are shown;

[0038] Figures 11A-11B Various cross-sectional views of an embodiment of a spar structure according to the present disclosure are shown, the spar structure being secured to a fixture capable of moving and lifting the spar structure;

[0039] Fig.12 A top view showing an embodiment of one of a plurality of workstations of a manufacturing facility for manufacturing and assembling wind turbine blades according to the present disclosure, particularly showing a plurality of subsets of wind turbine blade segments secured to a spar structure; and

[0040] Fig.13 shows a top view of an embodiment of a manufacturing facility for manufacturing and assembling wind turbine blades according to the present disclosure;

[0041] Fig.14 shows a perspective view of an embodiment of a manufacturing facility for manufacturing and assembling wind turbine blades according to the present disclosure;

[0042] Fig.15A shows an exploded side view of a fairing, particularly showing a fairing according to the present disclosure;

[0043] Fig. 15B It shows that according to the present disclosure Fig.15A A top exploded view of a fairing device; and

[0044] Fig. 15C Shows Figures 15A-15B1 is a top view of a fairing, particularly showing the fairing according to the present disclosure being assembled and attached to a wing spar structure. DETAILED DESCRIPTION

[0045] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are shown in the drawings. Each example is provided in a manner to explain the present invention rather than to limit the present invention. In fact, it will be appreciated by those skilled in the art that various modifications and variations may be made in the present invention without departing from the scope or spirit of the present invention. For example, a feature shown or described as a part of an embodiment may be used together with another embodiment to produce other further embodiments. Therefore, it is intended that the present invention encompasses such modifications and variations within the scope of the appended claims and their equivalents.

[0046] In general, the present disclosure relates to systems and methods for assembling wind turbine blades using a load-bearing spar structure and a supporting fixture, wherein the fixture is configured to move and / or lift the spar structure as the spar structure moves through an assembly line. Thus, in one embodiment, the spar structure has various positioning elements for positioning one or more wind turbine blade segments thereon. Thus, in one embodiment, the spar structure serves as both a structural member of the wind turbine blade and an assembly guide. Thus, as the spar structure moves through an assembly line, the wind turbine blade segments can be easily positioned thereon to assemble the wind turbine blade. Thus, the systems and methods of the present disclosure can improve the overall efficiency of wind turbine blade manufacturing.

[0047] Furthermore, in one embodiment, a manufacturing facility for housing the system of the present disclosure can be quickly set up and shut down at low cost. In one embodiment, a standard warehouse at a port can be rented during the assembly period. Furthermore, in one embodiment, the manufacturing facility can be built around a conveyor / mobile assembly line, where wind turbine blades continuously move through the manufacturing facility and are assembled as they progress toward an exit. Thus, in one embodiment, the manufacturing facility can focus on assembling and finishing sub-components that have been labeled green.

[0048] For example, in one embodiment, off-site manufactured subcomponents can be loaded into the above-mentioned manufacturing facility on either side of the mobile assembly line. Thus, in one embodiment, the length of the manufacturing facility can be up to about five (5) times the length of the finished wind turbine blades. In addition, in one embodiment, the side areas can be operated as kanbans on a just-in-time (JIT) system so that the mobile assembly line is not out of stock during the assembly process. In another embodiment, the systems and methods of the present disclosure may include a traffic light system for quickly responding to problems and / or failures. The systems and methods of the present disclosure are also capable of assembling multiple wind turbine blades simultaneously, for example, such as always having approximately seven wind turbine blades (or more or less) in a work-in-progress state. In such embodiments, when one wind turbine blade is completed, the blade root of another blade can be attached to the mobile assembly line to allow the process to continue.

[0049] The system and method can provide various advantages in the field of assembling wind turbine blades. For example, one of the advantages of having a load-bearing spar structure is the ability to create a manufacturing process on the fly. Specifically, if a spar cap is used instead, the spar cap cannot be used as a chassis. Therefore, manufacturing is more or less carried out in a static environment - that is, the necessary components are delivered to the same location and assembled in a mold. This requires the use of shared equipment (such as cranes), shared floor space, and creates inefficiencies. In contrast, the flowing or moving production line enabled by the load-bearing spar structure allows each workstation to be ideally optimized for production at that time.

[0050] Thus, the system and method can provide increased overall manufacturing efficiency by reducing various forms of waste (such as: overproduction - i.e., making more subassemblies than needed or earlier than needed; shortages - i.e., not having parts ready when needed; overmoving - i.e., having to shuttle back and forth through the building instead of working in a dedicated area; or waiting - i.e., using shared cranes and equipment currently in use elsewhere in the building). Furthermore, using the load-bearing spar structure as a transportable mobile chassis line enables lean manufacturing methods such as those described herein below.

[0051] Now refer to the figure, Figure 1 A perspective view of an embodiment of a wind turbine 10 according to the present disclosure is shown. As shown, the wind turbine 10 includes a tower 12 with a nacelle 14 mounted thereon. A plurality of wind turbine blades 16 are mounted on a rotor hub 18, which in turn is connected to a main flange of a rotating main rotor shaft. The wind turbine power generation and control components are housed within the nacelle 14. Figure 1The views are provided for illustrative purposes only to place the invention in an exemplary field of use. It should be understood that the invention is not limited to any particular type of wind turbine configuration. Furthermore, the invention is not limited to use with wind turbines, but can be used in any application involving the assembly of wind turbine blades.

[0052] Reference now Figure 2 and 3 , various views of a wind turbine blade 16 according to the present disclosure are shown. As shown, the wind turbine blade 16 shown has a segmented or modular configuration. It should also be understood that the wind turbine blade 16 may include any other suitable configuration now known or later developed in the art. As shown, the modular wind turbine blade 16 includes a main blade structure 15 and at least one blade segment 21 secured to the main blade structure 15. More specifically, as shown, the wind turbine blade 16 includes a plurality of blade segments 21.

[0053] More specifically, as shown, the main blade structure 15 may include any one or a combination of the following: a preformed blade root segment 20, a preformed blade tip segment 22, one or more continuous spar caps 48, 50, 51, 53, one or more shear webs 35 ( Figure 6-7 ), an additional structural member 52 fixed to the blade root section 20, and / or any other suitable structural member of the wind turbine blade 16. In addition, the blade root section 20 is configured to be mounted or otherwise fixed to the rotor 18 ( Figure 1 ). In addition, Figure 2 As shown in FIG. 1 , the wind turbine blade 16 defines a span 23 that is equal to the total length between the blade root section 20 and the blade tip section 22. Figure 2 and 6 , the wind turbine blade 16 also defines a chord 25 that is equal to the overall length between a leading edge 24 of the wind turbine blade 16 and a trailing edge 26 of the wind turbine blade 16. As is generally understood, the length of the chord 25 may generally vary relative to the span 23 as the wind turbine blade 16 extends from the blade root section 20 to the blade tip section 22.

[0054] Special References Figure 2-4 Any number of blade segments 21 or panels (also referred to herein as blade shells) of any suitable size and / or shape may be arranged generally along a longitudinal axis 27 in a generally span-wise direction between the blade root section 20 and the blade tip section 22. Thus, the blade segments 21 generally serve as an outer shell / cover for the wind turbine blade 16 and may define a generally aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section.

[0055] In additional embodiments, it should be understood that the blade segment portion of the blade 16 may include any combination of the segments described herein, without limitation to the depicted embodiments. More specifically, in certain embodiments, the blade segment 21 may include any one or combination of the following: pressure and / or suction side segments 44, 46 ( Figure 2 and 3 ), leading edge and / or trailing edge segments 40, 42 ( Figure 2-6 ), non-connected segments, single-connected segments, multi-connected blade segments, J-shaped blade segments or the like.

[0056] More specifically, if Figure 4 As shown in FIG. 1 , the leading edge segment 40 may have a forward pressure side surface 28 and a forward suction side surface 30 . Figure 5 As shown in , each trailing edge segment 42 may have a rear pressure side surface 32 and a rear suction side surface 34. Thus, the front pressure side surface 28 of the leading edge segment 40 and the rear pressure side surface 32 of the trailing edge segment 42 generally define the pressure side surface of the wind turbine blade 16. Similarly, the front suction side surface 30 of the leading edge segment 40 and the rear suction side surface 34 of the trailing edge segment 42 generally define the suction side surface of the wind turbine blade 16. In addition, as shown in Figure 6 As particularly shown in FIG. 1 , the leading edge segment 40 and the trailing edge segment 42 may be joined at the pressure side seam 36 and the suction side seam 38. For example, the blade segments 40, 42 may be configured to overlap at the pressure side seam 36 and / or the suction side seam 38. In addition, as Figure 2 , adjacent blade segments 21 may be configured to overlap at seams 54. Alternatively, in certain embodiments, the various segments of the wind turbine blade 16 may be secured together via an adhesive (or mechanical fastener) configured between overlapping leading and trailing edge segments 40, 42 and / or between overlapping adjacent leading or trailing edge segments 40, 42.

[0057] In a specific embodiment, Figure 2-3 6-7, the blade root segment 20 may include one or more longitudinally extending spar caps 48, 50. For example, the blade root segment 20 may be configured in accordance with U.S. Application No. 14 / 753,155, filed on June 29, 2015, entitled "Blade Root Segment for Modular Wind Turbine Blades and Methods of Making the Same," which is incorporated herein by reference in its entirety.

[0058] Similarly, the blade tip segment 22 may include one or more longitudinally extending spar caps 51, 53 infused therewith. More specifically, as shown, the spar caps 48, 50, 51, 53 may be configured to engage on opposing inner surfaces of the blade segment 21 of the wind turbine blade 16. Moreover, the blade root spar caps 48, 50 may be configured to align with the blade tip spar caps 51, 53. Thus, the spar caps 48, 50, 51, 53 may generally be designed to control bending stresses and / or other loads acting on the wind turbine blade 16 in a generally spanwise direction (a direction parallel to the span 23 of the wind turbine blade 16) during operation of the wind turbine 10. Moreover, the spar caps 48, 50, 51, 53 may be designed to withstand spanwise compression that occurs during operation of the wind turbine 10. Furthermore, the spar caps 48, 50, 51, 53, 53 may be configured to extend from the blade root segment 20 to the blade tip segment 22 or a portion thereof. Thus, in certain embodiments, the blade root segment 20 and the blade tip segment 22 may be coupled together via their respective spar caps 48, 50, 51, 53.

[0059] refer to Figure 6-7 One or more shear webs 35 may be configured between one or more spar caps 48, 50, 51, 53. More specifically, the shear webs 35 may be configured to increase the stiffness of the blade root section 20 and / or the blade tip section 22. Furthermore, the shear webs 35 may be configured to enclose the blade root section 20.

[0060] In addition, if Figure 2 and Figure 3 , an additional structural member 52 may be secured to the blade root segment 20 and extend in a generally span-wise direction to provide further support for the wind turbine blade 16. For example, the structural member 52 may be configured in accordance with U.S. Application No. 14 / 753,150, filed on June 29, 2015, entitled “Structural Member for a Modular Wind Turbine Blade,” which is incorporated herein by reference in its entirety. More specifically, the structural member 52 may extend any suitable distance between the blade root segment 20 and the blade tip segment 22. Thus, the structural member 52 is configured to provide additional structural support for the wind turbine blade 16 as well as to provide an optional mounting structure for the various blade segments 21 as described herein. For example, in certain embodiments, the structural member 52 may be secured to the blade root segment 20 and may extend a predetermined span-wise distance such that the leading edge segment 40 and / or the trailing edge segment 42 may be mounted thereto.

[0061] Generally speaking Figure 8-1 5 , shows a system and method for assembling a wind turbine blade, such as wind turbine blade 16 , according to the present disclosure. With particular reference to Figure 8, a flow chart of an embodiment of a method 100 for assembling a wind turbine blade 16 is shown. Figure 8 The steps performed in a particular order are depicted for purposes of illustration and discussion, but the methods described herein are not limited to any particular order or arrangement. Those skilled in the art using the disclosure provided herein will recognize that the various steps of the methods may be omitted, rearranged, combined and / or adjusted in various ways.

[0062] As shown at (102), method 100 includes providing a load-bearing spar structure having one or more locating features for locating one or more wind turbine blade segments thereon. In addition, the load-bearing spar structure is secured to a movable and / or extendable fixture. In addition, in an embodiment, the wind turbine blade segments can be any suitable wind turbine blade segments, such as those described herein, including but not limited to trailing edge segments, leading edge segments, pressure side segments, suction side segments, or the like. In addition, in an embodiment, and as will be described in more detail herein, the locating features can be grooves, protrusions, depressions, indicia, notches, or combinations thereof.

[0063] Still refer to Figure 8 As shown at (104), method 100 includes moving and / or extending a fixture so as to move and / or lift the load-bearing spar structure through an assembly line. For example, the movement or extension of the fixture can be achieved via a conveying device, such as a conveyor belt or one or more rolling elements (such as wheels and / or rollers). In further embodiments, the conveying device can also be a traction device and / or a robotic device or a mechanical arm. In additional embodiments, the conveying device can be operated continuously so as to continuously move the spar structure through the assembly line as the wind turbine blades are assembled on the assembly line. In another embodiment, the conveying device can be pulsed so as to drive the spar structure through the assembly line in a pulsed manner as the wind turbine blades are assembled on the assembly line. In addition, in one embodiment, if the conveying device is operated continuously, the spar structure can be continuously advanced through the assembly line while wind turbine blade segments are continuously added to the spar structure, thereby making the assembly process a streamlined process.

[0064] Thus, as the fixture moves and / or extends through the assembly line, as shown at (106), method 100 also includes positioning the wind turbine blade segment on the positioning feature of the load-bearing spar structure. For example, in one embodiment, positioning the wind turbine blade segment on the positioning feature can be done manually, or via a forklift, a robotic device, a crane, etc.

[0065] Still refer to Figure 8As shown at (108), method 100 includes securing the wind turbine blade segment to the load-bearing spar structure. For example, in one embodiment, the wind turbine blade segment may be secured to the spar structure by bonding the wind turbine blade segment to the spar structure via an adhesive. In another embodiment, the wind turbine blade segment may be secured to the spar structure using one or more fasteners.

[0066] refer to Figure 9-1 5. Better understanding Figure 8 Specifically, now refer to Fig. 9 , showing a method that can be used according to the present disclosure Figure 8 100 in a cross-sectional view of an embodiment of a spar structure 200 in the assembly method 100. In addition, such embodiments may be formed into a kit that can be used to Figure 8 The assembly method 100 of the present invention or the use of the embodiments and features described herein to assemble a wind turbine blade. As shown, in an embodiment, the spar structure 200 may include one or more shear web components 202, a first spar cap 204 and an opposing second spar cap 206. In a specific embodiment, as shown, the spar structure 200 may include two shear web components 202. In further embodiments, the spar structure 200 may include more than two or less than two shear web components 202.

[0067] In addition, as shown, the spar structure 200 may include one or more locating features 208 located on one or more of the shear web components 202 for locating one or more wind turbine blade segments 210 thereto. In further embodiments, the locating features 208 may also be located at any other suitable location on the spar structure 200. In further embodiments, the wind turbine blade segments 210 described herein may include one or more corresponding locating features 211. Thus, in an embodiment, the locating features 208, 211 may provide a predetermined mapping for placing one or more wind turbine blade segments 210 onto the spar structure 200. In such embodiments, the predetermined mapping defines a location on the spar structure 200 for each of the wind turbine blade segments 210.

[0068] Now special reference Figures 10A-10E , various embodiments of the positioning features 208, 211 of the present disclosure are shown. For example, Fig. 10A As shown in FIG. 2 , the locating features 208, 211 may include a locating plate 212 that may be secured to the spar structure 200 and / or the wind turbine blade segment 210 via one or more fasteners 216. In another embodiment, as shown in FIG. Fig. 10B, the locating features 208, 211 may include a groove 218 and a corresponding pin 220. In such embodiments, the groove 218 may be located on the spar structure 200 and the pin 220 may be located on the wind turbine blade segment 210, or vice versa. Furthermore, in an embodiment, the groove 218 and the pin 220 may be specifically shaped so that the groove 218 fits within the pin 220 and secures the wind turbine blade segment 210 to the spar structure 200.

[0069] like Fig. 10C , the locating features 208, 211 may include a plate 224 that is integrated and / or integral with the shear web 202 of the spar structure 200 and / or the wind turbine blade segment 210. Specifically, as shown, the plate 224 may also include one or more fasteners 222, such as stay bolts for receiving the plate 224 therethrough. In such embodiments, the spar structure 200 or the wind turbine blade segment 210 may be secured to the plate 224.

[0070] like Fig. 10D As shown in FIG. 2 , in one embodiment, the locating features 208 , 211 may include arcuate recesses 226 into which corresponding protrusions of the spar structure 200 and / or the wind turbine blade segment 210 may be inserted. Fig.10E , the locating features 208, 211 may include a first conical component 230 and a second conical component 232 that are sized to fit within the first conical component 230. In such embodiments, the first conical component 230 may be located on the spar structure 200 and the second conical component 232 may be located on the wind turbine blade segment 210, or vice versa. In general, various other types of locating features may also be used, such as grooves, protrusions, depressions, indicia, notches, or the like.

[0071] Reference now Figures 11A-11B , showing various views of an embodiment of a spar structure 200 described herein. As shown, the spar structure 200 is secured to and supported by a fixture 300. Thus, in one embodiment, the fixture 300 is configured to move and / or lift the spar structure 200 through an assembly line 402 (see, e.g., Fig.13 ). For example, as shown, the fixture 300 may include a conveyor 404 for advancing the spar structure 200 through the assembly line 402. In one embodiment, for example, Fig.11A and 11B As shown in FIG. 4 , the conveying device 404 can be a plurality of rolling elements 302, such as rollers or wheels. In another embodiment, the conveying device 404 can be a conveyor belt. In another embodiment,

[0072] Additionally, as shown, the fixture 300 may include a movable platform 304 configured to lift and / or move the spar structure 200 thereon. In such embodiments, the movable platform 304 may be used to facilitate attaching a wind turbine blade segment to the spar structure 200 by providing improved access to the locating features 208, 211. For example, Fig. 11B As shown in FIG. 1 , the fixture 300 may be extended upward to lift the spar structure 200 to a certain height.

[0073] In one embodiment, the spar structure 200 can be positioned on the fixture 300 in a variety of orientations. For example, Fig.11A As shown in FIG. 2 , the shear web 202 of the spar structure 200 may be oriented vertically, and the bottom of the spar structure 200 may be placed on the fixture 300. Fig. 11B , the shear webs 202 may be oriented horizontally, and one shear web 202 may be placed on the fixture 300. The orientation of the spar structure 200 may be changed as desired while the spar structure 200 is being used to assemble a modular wind turbine blade, as will be discussed herein below.

[0074] Reference now Fig.12 , shows a top view of an embodiment of components for assembling a modular wind turbine blade 16 according to the present disclosure. Specifically, as shown, the wind turbine blade 16 can be composed of a plurality of different subsets 427, 429, 432, 436 of wind turbine blade segments assembled to the spar structure 200. More specifically, as shown, the subsets 427, 429, 432, 436 of wind turbine blade segments 210 can include one or more blade root segments 426, one or more blade tip segments 428, one or more trailing edge segments 430, one or more leading edge segments 434, and / or combinations thereof, respectively. For example, in an embodiment, the subsets of blade root segments 426 can be joined together before being secured to the spar structure 200 to form the blade root segment 20 of the wind turbine blade 16. The joined blade root segments 426 can then be secured to the spar structure 200 to form the blade root segment 20. A similar process may be repeated for each subset as needed to assemble different regions of the wind turbine blade 16. In such embodiments, the plurality of subsets 427, 429, 432, 436 of wind turbine blade segments 210 may be secured to the spar structure 200, e.g., using adhesives, fasteners, etc., to form the wind turbine blade 16.

[0075] Reference now Fig.13 and 14, various views of a manufacturing facility 400 for manufacturing and assembling wind turbine blades according to the present disclosure are shown. For example, as shown, the manufacturing facility 400 may include an assembly line 402. Specifically, as shown, the assembly line 402 may include a plurality of stations 406, 408, 410, 412 arranged in sequence for assembling wind turbine blades 16. The stations may include, for example, a first station 406, a second station 408, a third station 410, and a fourth station 412. However, it should be understood that any suitable number of stations may be included in the assembly line 402, including more than four or less than four stations.

[0076] More specifically, in an embodiment, each station 406, 408, 410, 412 may include a different subset of one or more wind turbine blade segments 210 (e.g., any one of the subsets 427, 429, 432, 436) for positioning onto the load-bearing spar structure 200. Thus, in an embodiment, as the spar structure 200 moves along the assembly line 402, a different subset 427, 429, 432, 436 of wind turbine blade segments 210 may be assembled and secured to the spar structure 200 at each station 406, 408, 410, 412. Furthermore, in an embodiment, the assembly line 402 may include one or more supply lines 414 for feeding the subsets 427, 429, 432, 436 of wind turbine blade segments 210 into the assembly line 402.

[0077] In one embodiment, for example, the spar structure 200 may be moved to the first station 406 via the conveyor 404 , or the spar structure 200 may be manually placed on the conveyor 404 at the first station 406 .

[0078] Thus, in one embodiment, the conveyor 404 may be operated in a continuous or discontinuous manner. For example, in one embodiment, the conveyor 404 may be operated to continuously move the spar structure 200 through the assembly line 402 when assembling the wind turbine blade 16, for example, using a conveyor belt. Furthermore, in one embodiment, if the conveyor 404 is operated continuously, the spar structure 200 may be continuously advanced through each station 406, 408, 410, 412 while the wind turbine blade segments 210 are continuously attached to the spar structure 200. In alternative embodiments, the conveyor 404 may be stopped and started at each station manually (e.g., using the roller element 302) or automatically (e.g., using a controller controlling the conveyor 404). Specifically, in one embodiment, the conveyor 404 may be moved through the assembly line 402 in a pulsed manner such that the spar structure 200 is paused at each station 406, 408, 410, 412 in order to attach the wind turbine blade segments 210 to the spar structure 200. In another embodiment, the conveyor 404 may also pulse through some of the workstations 406 , 408 , 410 , 412 while continuously moving through the remaining workstations 406 , 408 , 410 , 412 .

[0079] Still refer to Fig.13 and 14 In one embodiment, at the first station 406, the locating features 208 may be attached to the spar structure 200 to prepare the spar structure 200 for attachment of the wind turbine blade segments 210 described herein. In another embodiment, the spar structure 200 may be formed such that the locating features 208 are integral thereto. Further, in one embodiment, a first subset 427 of the wind turbine blade segments 210 may be secured to the spar structure 200 at the first station 406 of the assembly line 402. For example, in one embodiment, the first subset 427 of the wind turbine blade segments may include at least one or more blade root segments 426 for forming the blade root segments 20 of the wind turbine blade 16. Thus, in one embodiment, the blade root segments 20 may be placed onto the spar structure 200 and secured thereto at the first station 406.

[0080] As shown at one or more intermediate stations, such as the second station 408 and the third station 410, the second and third intermediate subsets 432, 436 of wind turbine blade segments may be respectively secured to the spar structure 200. For example, in an embodiment, the second and third intermediate subsets 432, 436 of wind turbine blade segments may include at least one or more trailing edge segments 430, one or more leading edge segments 434, a pressure side segment, a suction side segment, and / or combinations thereof.

[0081] Therefore, if Fig.14436, the supply lines 416, 418 may deliver subsets of wind turbine blade segments, such as the second and third intermediate subsets 432, 436 discussed above, to the spar structure 200 at the second station 408. Furthermore, as shown, the second and third intermediate subsets 432, 436 of wind turbine blade segments may be comprised of different segments that may be joined together and then secured to the spar structure 200. For example, the second and third intermediate subsets 432, 436 of wind turbine blade segments may include a first segment 420 and a different second segment 422 that are secured to each other to form the intermediate subsets 432, 436. Furthermore, the first and second segments 420, 422 may include locating features 211, 213 to assist in securing to each other to form the intermediate subsets 432, 436 or to the spar structure 200 to form the wind turbine blade 16.

[0082] Additionally, as shown, the second station 408 may include one or more supply lines 414 configured to supply one or more wind turbine blade segments 210 or subsets into the assembly line 402. For example, the supply line 414 may supply wind turbine blade segments or subsets of wind turbine blade segments from an area outside the manufacturing facility 400 to an area of ​​the assembly line 402 adjacent to the spar structure 200 for assembly and securing thereto. For example, in one embodiment, the supply line 414 may also include a conveyor belt or the like. Additionally, as shown, the supply line 414 may include one or more supply lines 414 configured to supply one or more wind turbine blade segments 210 or subsets thereof into the assembly line 402. For example, the supply line 414 may also include a conveyor belt or the like. Fig.13 As shown in FIG. 4 , the supply line 414 may include one or more supply line branches 416, 418. Fig.13 Two supply line branches 416, 418 are shown, but it should be understood that any number of supply line branches 416, 418 may be used depending on the wind turbine blade segments and / or subsets of wind turbine blade segments to be attached. The second and third intermediate subsets 432, 436 of wind turbine blade segments may then be secured to the spar structure 200.

[0083] Furthermore, in one embodiment, if Fig.13 and 14 As shown in FIG. 4 , the spar structure 200 may be transferred through the assembly line 402 to a terminal station, such as the fourth station 412. Additionally, in one embodiment, a fourth subset 429 of wind turbine blade segments may be secured to the spar structure 200 at the fourth station 412 of the assembly line 402. For example, in one embodiment, Fig.14 As shown in FIG. 4 , a fourth subset 429 of wind turbine blade segments may include at least one or more blade tip segments 428 ( Fig.12 ). In addition, if Fig.13, the fourth station 412 may also include one or more supply lines 414. Thus, at the fourth station 412, the blade tip segment 428 may be assembled and secured to the spar structure 200 to complete the wind turbine blade 16, for example, using one or more adhesives, fasteners, or any other suitable means.

[0084] Special References Fig.14 , the crane 424 may be used to position the wind turbine blade segments onto the spar structure 200 at the positioning features 208 of the spar structure 200. In particular, the crane 424 may assist in assembling the wind turbine blade segments or a subset of wind turbine blade segments onto the spar structure 200. Other methods may also be used to assemble the wind turbine blade segments or a subset of wind turbine blade segments onto the spar structure 200. For example, an operator, a robotic arm, or the like may also be used in the assembly.

[0085] Reference now Figures 15A-15C , showing various views of a fairing device according to the present disclosure and a method of assembling the same to a wind turbine blade. Specifically, Fig.15A and 15B Various views of a fairing 438 according to the present disclosure are shown. Fig. 15C FIG. 4 shows a top view of a fairing 438 assembled to a wing spar structure 200 according to the present disclosure. Fig.15A As shown in FIG. 4 , fairing 438 may include aerodynamic surface 442 and trailing edge portion 440. Aerodynamic surface 442 and trailing edge portion 440 together may form additional subset 444. Fig. 15C , one or more of the locating features 211 described herein may be included on the aerodynamic surface 442. Thus, in one embodiment, the fairing 438 may be secured to the spar structure 200 via the locating features 208, 211. Similar to the fairing 438, other aerodynamic features may be assembled into additional subsets and secured to the spar structure 200. For example, in addition to the fairing 438, the aerodynamic features may include vortex generators, guide fences, or the like.

[0086] Various aspects and embodiments of the present invention are defined by the following numbered clauses:

[0087] Clause 1. A method of assembling a wind turbine blade, the method comprising:

[0088] providing a load-bearing spar structure having one or more locating features for locating one or more wind turbine blade segments, the load-bearing spar structure being secured to a fixture, the fixture being movable and extendable;

[0089] at least one of moving and extending the fixture to at least one of move and lift the load-bearing spar structure through the assembly line;

[0090] positioning one or more wind turbine blade segments onto one or more locating features of the load-bearing spar structure while at least one of moving and extending the fixture through the assembly line; and

[0091] One or more wind turbine blade segments are secured to the load-bearing spar structure.

[0092] Clause 2. The method of clause 1, wherein at least one of the moving or extending of the fixture is accomplished via a conveying device.

[0093] Clause 3. The method of clause 2, further comprising continuously operating the conveyor device through the assembly line to assemble the wind turbine blades.

[0094] Clause 4. The method of clause 2, further comprising pulsing the conveyor through an assembly line to assemble the wind turbine blades.

[0095] Clause 5. A method as recited in any of the preceding clauses, wherein the assembly line comprises a plurality of workstations, each workstation comprising a different subset of one or more wind turbine blade segments for positioning onto a load-bearing spar structure, the method further comprising: assembling a subset of the one or more wind turbine blade segments onto the load-bearing spar structure at the plurality of workstations, and securing a subset of the one or more wind turbine blades to the spar structure at the plurality of workstations.

[0096] Clause 6. The method of Clause 5, further comprising:

[0097] A subset of one or more wind turbine blade segments is fed into the assembly line via one or more supply lines.

[0098] Clause 7. The method of clauses 5-6, wherein the first subset of one or more wind turbine blade segments at the first station of the assembly line includes at least a blade root segment, the method further comprising positioning the blade root segment onto the load-bearing spar structure at the first station.

[0099] Clause 8. The method of clauses 5-7, wherein one or more intermediate subsets of one or more wind turbine blade segments at one or more intermediate stations of the assembly line include at least one of a leading edge segment, a trailing edge segment, a pressure side segment, or a suction side segment, and the method further includes positioning the one or more intermediate subsets of one or more wind turbine blade segments on a load-bearing spar structure at the one or more intermediate stations.

[0100] Clause 9. The method of clauses 5-8, wherein the additional subset of one or more wind turbine blade segments at the terminal station of the assembly line includes at least a blade tip segment, the method further comprising positioning the blade tip segment onto the load-bearing spar structure at the terminal station.

[0101] Clause 10. The method of clause 9, wherein an additional subset of the one or more wind turbine blade segments at a terminal station of the assembly line comprises one or more aerodynamic blade features, the method further comprising positioning the one or more aerodynamic blade features on a load-bearing spar structure at the terminal station.

[0102] Clause 11. The method of clause 10, wherein the one or more aerodynamic blade features include at least one of a vortex generator, a fairing, or a flow fence.

[0103] Clause 12. The method of clauses 9-11, wherein securing the one or more wind turbine blade segments to the load-bearing spar structure further comprises bonding the one or more wind turbine blade segments to the load-bearing spar structure via one or more adhesives at a terminal station of the assembly line.

[0104] Clause 13. The method of any of the preceding clauses, wherein positioning one or more wind turbine blade segments on one or more positioning features of the load-bearing spar structure further comprises positioning one or more of the one or more wind turbine blade segments on one or more positioning features of the load-bearing spar structure using a crane.

[0105] Clause 14. The method of any of the preceding clauses, wherein the one or more locating features include at least one of a groove, a protrusion, a depression, a mark, an indentation, or a combination thereof.

[0106] Clause 15. The method of any of the preceding clauses, wherein the load-bearing spar structure comprises a first spar cap, a second spar cap, and a shear web disposed between the first spar cap and the second spar cap.

[0107] Clause 16. The method of clause 15, wherein at least one of the one or more locating features is located on the shear web.

[0108] Clause 17. A kit for assembling a wind turbine blade, the kit comprising:

[0109] a load-bearing spar structure including one or more locating features;

[0110] a fixture supporting the load-bearing spar structure, the fixture being movable along at least one axis and extendable about at least one axis;

[0111] An assembly line comprising a plurality of stations arranged along at least one axis and a conveyor secured to a fixture for moving the fixture along the at least one axis to each of the plurality of stations;

[0112] one or more wind turbine blade segments attachable to the one or more locating features of the load-bearing spar structure, the one or more wind turbine blade segments comprising one or more subsets of wind turbine blade segments, at least one of the subsets of wind turbine blade segments being positioned at each of the plurality of stations; and

[0113] A predetermined map is provided for placing one or more wind turbine blade segments onto a load-bearing spar structure, the predetermined map defining a position for each of the one or more wind turbine blade segments on one or more locating features of the load-bearing spar structure.

[0114] Clause 18. The kit of Clause 17, wherein the plurality of work stations includes a first work station including a first subset of one or more wind turbine blade segments, the first subset including at least a blade root segment.

[0115] Clause 19. The kit of clause 18, wherein the plurality of work stations comprises one or more intermediate work stations, the one or more intermediate work stations comprising one or more intermediate subsets of one or more wind turbine blade segments, the one or more intermediate subsets comprising at least one of a leading edge segment, a trailing edge segment, a pressure side segment, or a suction side segment.

[0116] Clause 20. The kit of Clause 19, wherein the plurality of work stations includes a terminal work station including an additional subset of one or more wind turbine blade segments, the terminal work station including at least a blade tip segment.

[0117] Those skilled in the art will recognize the interchangeability of various features in different embodiments. Similarly, those of ordinary skill in the art can mix and match the various method steps and features described and other known equivalents of each such method and feature to build additional systems and techniques according to the principles of the present disclosure. Of course, it should be understood that not necessarily all such purposes or advantages described above can be achieved according to any particular embodiment. Therefore, for example, those skilled in the art will recognize that the systems and techniques described herein can be embodied or performed in a manner that realizes or optimizes an advantage or a group of advantages taught herein, without necessarily realizing other purposes or advantages as may be taught or implied herein.

[0118] Although only certain features of the present invention have been shown and described herein, many modifications and changes may occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all modifications and changes that fall within the true spirit of the invention.

[0119] This written description uses examples to disclose the invention, including the best mode, and also to enable those skilled in the art to practice the invention, including making and using any devices or systems and performing any combined methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. These other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A method of assembling a wind turbine blade, the method comprising: providing a load-bearing spar structure having one or more locating features for locating one or more wind turbine blade segments, the load-bearing spar structure being secured to a fixture, the fixture being movable and extendable; at least one of moving and extending the fixture to at least one of move and lift the load-bearing spar structure through an assembly line; positioning the one or more wind turbine blade segments onto the one or more locating features of the load-bearing spar structure while at least one of moving and extending the fixture through the assembly line; as well as The one or more wind turbine blade segments are secured to the load-bearing spar structure.

2. The method according to claim 1, wherein: The at least one of the movement or extension of the fixing device is achieved via a conveying device. 3 . The method of claim 2 , further comprising continuously operating the conveyor through the assembly line to assemble the wind turbine blades.

4. The method of claim 2, further comprising pulsing the conveyor through the assembly line to assemble the wind turbine blades.

5. The method according to claim 1, wherein: The assembly line comprises a plurality of workstations, each workstation comprising a different subset of the one or more wind turbine blade segments for positioning onto the load-bearing spar structure, the method further comprising: assembling the subset of the one or more wind turbine blade segments onto the load-bearing spar structure at the plurality of workstations, and fixing the subset of the one or more wind turbine blades to the spar structure at the plurality of workstations.

6. The method according to claim 5, further comprising: The subset of the one or more wind turbine blade segments is fed into the assembly line via one or more supply lines.

7. The method according to claim 5, wherein: The first subset of the one or more wind turbine blade segments at a first station of the assembly line includes at least a blade root segment, the method further comprising positioning the blade root segment onto the load-bearing spar structure at the first station.

8. The method according to claim 5, wherein: The one or more intermediate subsets of the one or more wind turbine blade segments at the one or more intermediate stations of the assembly line include at least one of a leading edge segment, a trailing edge segment, a pressure side segment or a suction side segment, and the method further includes positioning the one or more intermediate subsets of the one or more wind turbine blade segments on the load-bearing spar structure at the one or more intermediate stations.

9. The method according to claim 5, wherein: The additional subset of the one or more wind turbine blade segments at a terminal station of the assembly line includes at least a blade tip segment, the method further comprising positioning the blade tip segment onto the load-bearing spar structure at the terminal station.

10. The method according to claim 9, wherein: The additional subset of the one or more wind turbine blade segments at a terminal station of the assembly line includes one or more aerodynamic blade features, the method further comprising positioning the one or more aerodynamic blade features onto the load-bearing spar structure at the terminal station.

11. The method according to claim 10, wherein: The one or more aerodynamic blade features include at least one of a vortex generator, a fairing, or a flow fence.

12. The method according to claim 9, wherein: Securing the one or more wind turbine blade segments to the load-bearing spar structure further includes bonding the one or more wind turbine blade segments to the load-bearing spar structure via one or more adhesives at a terminal station of the assembly line.

13. The method according to claim 1, wherein: Positioning the one or more wind turbine blade segments to the one or more locating features of the load-bearing spar structure further includes positioning one or more of the one or more wind turbine blade segments to the one or more locating features of the load-bearing spar structure using a crane.

14. The method according to claim 1, wherein: The one or more positioning features include at least one of a groove, a protrusion, a depression, a mark, an indentation, or a combination thereof.

15. The method according to claim 1, wherein: The load-bearing spar structure includes a first spar cap, a second spar cap, and a shear web arranged between the first spar cap and the second spar cap.

16. The method according to claim 15, wherein: At least one locating feature of the one or more locating features is located on the shear web.

17. A kit for assembling a wind turbine blade, the kit comprising: a load-bearing spar structure comprising one or more locating features; a fixture supporting the load-bearing spar structure, the fixture being movable along at least one axis and extendable about at least one axis; an assembly line comprising a plurality of stations arranged along the at least one axis and a conveyor fixed to the fixture, the conveyor being used to move the fixture along the at least one axis to each of the plurality of stations; one or more wind turbine blade segments attachable to the one or more locating features of the load-bearing spar structure, the one or more wind turbine blade segments comprising one or more subsets of wind turbine blade segments, at least one of the subsets of wind turbine blade segments being positioned at each of the plurality of stations; as well as A predetermined map is provided for placing the one or more wind turbine blade segments onto the load-bearing spar structure, the predetermined map defining a position on the one or more locating features of the load-bearing spar structure for each of the one or more wind turbine blade segments.

18. The kit of claim 17, wherein: The plurality of work stations includes a first work station including a first subset of the one or more wind turbine blade segments, the first subset including at least a blade root segment.

19. The kit of claim 18, wherein: The plurality of work stations include one or more intermediate work stations including one or more intermediate subsets of the one or more wind turbine blade segments, the one or more intermediate subsets including at least one of a leading edge segment, a trailing edge segment, a pressure side segment, or a suction side segment.

20. The kit of claim 19, wherein: The plurality of work stations includes a terminal work station including an additional subset of the one or more wind turbine blade segments, the terminal work station including at least a blade tip segment.

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