Movable assembly fixture for a rotor blade

Abstract

A method for assembling a rotor blade includes securing a blade root section of the rotor blade to a movable assembly fixture. The movable assembly fixture has a counterbalance for stabilizing the blade root section in the movable assembly fixture. The method also includes transporting the movable assembly fixture adjacent to a mold of the rotor blade. The mold has one or more fiber layers placed therein. The method includes aligning the blade root section with the mold via the movable assembly fixture. Moreover, the method includes vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at a predetermined angle. Further, the method includes infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

Description

MOVABLE ASSEMBLY FIXTURE FOR A ROTOR BLADEFIELD

[0001] The present disclosure relates generally to wind turbines, and more particularly to an assembly fixture for wind turbine rotor blades.BACKGROUND

[0002] Wind power is considered one of the cleanest, most environmentally friendly energy sources presently available, and wind turbines have gained increased attention in this regard. A modem wind turbine ty pically includes a tower, a generator, a gearbox, a nacelle, and one or more rotor blades. The rotor blades capture kinetic energy of wind using known airfoil principles and transmit the kinetic energy in the form of rotational energy so as to turn a shaft coupling the rotor blades to a gearbox, or if a gearbox is not used, directly to the generator. The generator then converts the mechanical energy to electrical energy that may be deployed to a utility grid.

[0003] The construction of a modem rotor blade generally includes one or more skin layers, shell components, opposing spar caps, and one or more shear webs extending between the opposing spar caps. The skin layer(s) is typically manufactured from layers of fiber composite and a lightweight core material and forms the exterior aerodynamic airfoil shape of the rotor blade. Further, the spar caps provide increased rotor blade strength and / or stiffness by providing structural elements along the span of the rotor blade on both interior sides of the rotor blade. Moreover, spar caps are typically constructed from fiber reinforced composites. The shear web(s) generally include structural beam-like components that extend essentially perpendicularly between the opposing spar caps and across the interior portion of the rotor blade between the outer skin layers.

[0004] The size, shape, and / or weight of rotor blades are factors that contribute to energy efficiencies of wind turbines. An increase in rotor blade size increases the energy production of a wind turbine, while a decrease in blade mass also furthers the efficiency of a wind turbine. Furthermore, as the size of wind turbines increases, particularly the size of the rotor blades, so do the respective costs ofmanufacturing, transporting, and assembly of the wind turbines. The economic benefits of increased wind turbine sizes must be weighed against these factors.

[0005] A known method of molding and / or assembling a rotor blade includes initially forming a blade root section of the rotor blade at a first location at a facility, lifting the formed blade root section at the first location via an overhead crane atop a mold of the rotor blade at a second location at the facility, subsequently forming the rotor blade in the mold by forming a blade shell and joining the blade shell to the blade root section. However, the aforementioned overhead crane poses safety challenges (e.g., due to operators working under a suspended load) and increased as the blade root section is required to be suspended above operators at the facility.

[0006] Accordingly, the art is continuously seeking new and improved technologies for assembling wind turbine rotor blades.BRIEF DESCRIPTION

[0007] 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.

[0008] In an aspect, the present disclosure is directed to a method for assembling a rotor blade. The method includes securing a blade root section of the rotor blade to a movable assembly fixture. The movable assembly fixture has a counterbalance for stabilizing the blade root section in the movable assembly fixture. The method also includes transporting the movable assembly fixture adjacent to a mold of the rotor blade. The mold has one or more fiber layers placed therein. The method includes aligning the blade root section with the mold via the movable assembly fixture. Moreover, the method includes vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at a predetermined angle. Further, the method includes infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

[0009] In another aspect, the present disclosure is directed to a movableassembly fixture for assembling a rotor blade. The movable assembly fixture includes a frame structure and one or more arm members for receiving a root plate. The root plate is configured to secure a blade root section on a first side of the frame structure. The movable assembly fixture also includes a counterbalance mounted on a second side of the frame structure for balancing a weight of the blade root section. Further, the movable assembly fixture includes a plurality of rollers mounted to a bottom side of the frame structure for allowing movement of the movable assembly fixture. Moreover, the movable assembly fixture includes a lifting assembly for lifting and lowering the blade root section onto a mold of the rotor blade at a predetermined angle atop one or more fiber layers in the mold.

[0010] 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 invention and, together with the description, serve to explain the principles of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

[0012] FIG. 1 illustrates a perspective view of an embodiment of a wind turbine according to the present disclosure;

[0013] FIG. 2 illustrates a perspective view of one of the rotor blades of FIG. 1;

[0014] FIG. 3 illustrates a cross-sectional view of an embodiment of a rotor blade according to the present disclosure;

[0015] FIG. 4 illustrates a front view of an embodiment of an assembly jig for a blade root section of a rotor blade according to the present disclosure;

[0016] FIG. 5 illustrates a perspective view of an embodiment of a movable assembly fixture for assembling a rotor blade according to the present disclosure, particularly illustrating the movable assembly fixture in a lowered position;

[0017] FIG. 6 illustrates a perspective view of an embodiment of a movable assembly fixture for assembling a rotor blade according to the present disclosure,particularly illustrating the movable assembly fixture in a raised position;

[0018] FIG. 7 illustrates a perspective view of an embodiment of a movable assembly fixture for assembling a rotor blade arranged adjacent to a mold of the rotor blade according to the present disclosure; and

[0019] FIG. 8 illustrates a flow diagram of an embodiment of a method for assembling a rotor blade according to the present disclosure.DETAILED DESCRIPTION

[0020] Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of an embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

[0021] Generally, the present disclosure is directed to a movable assembly fixture that can lift, transport, and install a pre-assembly blade root section of a rotor blade without using an overhead crane. The movable assembly fixture may be used for static molds, pulse manufacturing, and / or moving assembly lines. As such, the movable assembly fixture mitigates operators needing to work under suspended loads during installation of the blade root section into shell molding. In particular embodiments, for example, a self-contained vertical lift device (e.g., battery powered) is configured to position the blade root section in the mold at a predetermined angle, such as a 5 degree angle. For example, a pallet jack or similar can position the blade root section in place adjacent to the mold, which can then be guided with a rail system to secure positioning by the mold. The blade root section can then be lowered into place at the desired angle prior to final mounting.

[0022] It should be appreciated that, although the present disclosure will generally be described herein with reference to components of a wind turbine, thedisclosed method may be generally used to bond any two or more composite parts along a joint.

[0023] Referring now to the drawings, FIG. 1 illustrates a perspective view of an embodiment of a wind turbine 10 according to the present disclosure. As shown, the wind turbine 10 includes a tow er 12 with a nacelle 14 mounted thereon. A plurality of rotor blades 16 are mounted to a rotor hub 18, which is in turn connected to a main flange that turns a main rotor shaft (not shown). The wind turbine power generation and control components are housed within the nacelle 14. The view of FIG. 1 is provided for illustrative purposes only to place the present invention in an exemplary field of use. It should be appreciated that the invention is not limited to any particular type of wind turbine configuration.

[0024] Referring now to FIG. 2, a perspective view of an embodiment of a rotor blade 16 of the wind turbine 10 of FIG. 1 according to the present disclosure is shown. As show n, the rotor blade 16 may include a plurality of individual blade segments 20 aligned in an end-to-end or side-by-side configuration from a blade tip 22 to a blade root 24. Further, as shown, each of the individual blade segments 20 may be uniquely configured so that the plurality of blade segments 20 define a complete rotor blade 16 having a designed aerodynamic profile, length, and other desired characteristics. For example, each of the blade segments 20 may have an aerodynamic contour that corresponds to the aerodynamic contour of adjacent blade segments 20. Thus, the aerodynamic contours of the blade segments 20 may form a continuous aerodynamic contour of the rotor blade 16. As such, the rotor blade 16 may include any suitable number of segments 20. For example, as show n, the rotor blade 16 includes three rotor blade segments 20. It should be understood, however, that the rotor blade 16 may have any suitable number of blade segments 20, such as less than three or more than three, such as four or more.

[0025] In general, the rotor blade 16 may include a pressure side 32 and a suction side 34 extending between a leading edge 36 and a trailing edge 38. Additionally, the rotor blade 16 may have a span 42 extending along a span- wise axis 43 and a chord 44 extending along a chord-wise axis 40. Further, as shown, the chord 44 may change throughout the span 42 of the rotor blade 16. Thus, a local chord may be defined at any span- wise location on the rotor blade 16 or anyblade segment 20 thereof.

[0026] The rotor blade 16 may, in an embodiment, be curved. Curving of the rotor blade 16 may entail bending the rotor blade 16 in a generally flap wise direction and / or in a generally edgewise direction. The flapwise direction is a direction substantially perpendicular to a transverse axis through a cross-section of the widest side of the rotor blade 16. Alternatively, the flapwise direction may be construed as the direction (or the opposite direction) in which the aerodynamic lift acts on the rotor blade 16. The edgewise direction is perpendicular to the flapwise direction. Flapwise curvature of the rotor blade 16 is also know n as pre-bend, while edgewise curvature is also known as sw eep. Thus, a curved rotor blade 16 may be pre-bent and / or swept. Curving may enable the rotor blade 16 to better withstand flapwise and edgewise loads during operation of the wind turbine 10 and may further provide clearance for the rotor blade 16 from the tower 12 during operation of the wind turbine 10.

[0027] In an embodiment, as shown in FIGS. 2 and 3, the blade segments 20 may include, at least, a first blade segment 21 and a second blade segment 23. Further, as shown, the first and second blade segments 21, 23 may include a pressure side surface 32 or a suction side surface 34. Further, as shown in FIG. 3, the rotor blade 16 may include one or more structural components, such as a beam structure 46 that includes spar caps 48, 50 on either or both of the pressure or suction sides 32, 34 of the rotor blade 16. In addition, the rotor blade 16 may also include one or more shear webs 52 extending betw een the spar caps 48, 50. It should be understood that although a beam configuration is shown, any other suitable structural configuration may also be included in the rotor blade 16.

[0028] Referring now to FIG. 4, the blade root 24, also referred to herein as a blade root section 110, may be formed in an assembly jig 54 at a first location. In such embodiments, the assembly jig 54 is configured to support a root plate 108. As such, in an embodiment, the blade root section 110 can be formed on and secured to the root plate 108.

[0029] Referring now to FIGS. 5-7, the present disclosure is directed to a movable assembly fixture 100 for assembling a rotor blade, such as rotor blade 16. More specifically, as shown, the assembly fixture 100 includes a frame structure102 and one or more arm members 104, 106 for receiving the root plate 108. Thus, as shown, the root plate 108 is configured to secure the blade root section 110 on a first side 1 12 of the frame structure 102. More specifically, in an embodiment, the arm member(s) 104, 106 may include a first arm member 104 and a second arm member 106. As such, in an embodiment, the root plate 108 may include first and second through holes 126, 128 sized to receive the first and second arm members 104. 106 of the movable assembly fixture 100.

[0030] Furthermore, as shown, the movable assembly fixture 100 also includes a counterbalance 116 mounted on a second side 114 of the frame structure 102 for balancing a w eight of the blade root section 110. Thus, in such embodiments, the counterbalance 116 can be sized to offset the weight of the blade root section 110.

[0031] Moreover, as shown in FIGS. 5-8, the movable assembly fixture 100 further includes a plurality of rollers 118 mounted to a bottom side 120 of the frame structure 102 for allowing movement of the movable assembly fixture 100. For example, in an embodiment, the rollers 118 allow the movable assembly fixture 100 to be moved (e.g.. rolled) around a manufacturing facility to and from various locations so as to avoid the use of an overhead crane. Furthermore, in an embodiment, the movable assembly fixture 100 may be rolled to various locations via a pallet jack or any other suitable automatic guided vehicle.

[0032] In addition, as shown in FIGS. 5-7, the movable assembly fixture 100 also includes a lifting assembly 122 for lifting and lowering the blade root section 110 onto a mold 124 (FIG. 8) of the rotor blade at a predetermined angle atop one or more fiber layers 125 in the mold 124, e.g. without contacting the applied material in the mold 124. More specifically, in an embodiment, the lifting assembly 122 may include first and second support members 130, 132 supporting the first and second arm members 104, 106. Furthermore, in an embodiment, the lifting assembly 122 may include a hydraulic system, an actuator system, a lift, or similar. For example, in an embodiment, the first and second arm members 104, 106 may be welded or otherwise secured to the first and second support members 130, 132. Moreover, as shown, the first and second arm members 104, 106 may extend generally perpendicular to the first and second support members 130, 132.

[0033] Referring particularly to FIG. 8, the movable assembly fixture 100 mayfurther include a rail system 134 for aligning the movable assembly fixture 100 adjacent to the mold 124. Thus, in an embodiment, the automatic guided vehicle (e.g., the pallet jack) is configured to transport the movable assembly fixture 100 having the blade root section 110 secured thereto from an assembly jig where it is originally formed to a location near the mold 124 of the rotor blade 16 by engaging the plurality of rollers 118. The rollers 118 of the movable assembly fixture 100 can then be aligned with the rail system 134 such that the movable assembly fixture 100 can be moved to a precise location adjacent to the mold 124.

[0034] In additional embodiments, as shown in FIG. 8, the movable assembly fixture 100 may further include one or more alignment features 136, 138 for aligning the blade root section 110 with the mold 124. More specifically, as shown, the alignment feature(s) 136, 138 may include a first hook member 136 and a second hook member 138 on opposing sides of the movable assembly fixture 100 that align with corresponding hook members 140 of the mold 124.

[0035] Referring now to FIG. 9, a flow diagram of an embodiment of a method 200 for assembling a rotor blade, such as rotor blade 16, is illustrated. In general, the method 200 is described herein as relating to wind turbine rotor blades, such as the rotor blade 16 and the movable assembly fixture 100 described herein.However, it should be appreciated that the disclosed method 200 may be implemented using any other suitable rotor blades now known or later developed in the art and is also not limited to wind turbines. In addition, although FIG. 9 depicts steps performed in a particular order for purposes of illustration and discussion, the methods described herein are not limited to any particular order or arrangement. One skilled in the art, using the disclosures provided herein, will appreciate that various steps of the methods can be omitted, rearranged, combined and / or adapted in various ways.

[0036] As shown at (202), the method 200 includes securing a blade root section 110 of the rotor blade 16 to a movable assembly fixture 100, the movable assembly fixture 100 having a counterbalance 116 for stabilizing the blade root section 110 in the movable assembly fixture 100. In an embodiment, for example, securing the blade root section 110 of the rotor blade 16 to the movable assembly fixture 100 may include securing the root plate 108 having the blade root section110 formed on and secured thereto to the movable assembly fixture 100.

[0037] In particular embodiments, for example, the method 200 may also include forming the blade root section 110 of the rotor blade 16 in the assembly jig 54 at a first location. In such embodiments, the assembly jig 54 is configured to support the root plate 108. As such, in an embodiment, the blade root section 110 is formed on and secured to the root plate 108.

[0038] Further, as shown at (204), the method 200 includes transporting the movable assembly fixture 100 adjacent to a mold 124 of the rotor blade 16, the mold 124 having one or more fiber layers 125 placed therein. For example, in an embodiment, transporting the movable assembly fixture 100 adjacent to the mold 124 of the rotor blade 16 may include rolling the movable assembly fixture 100 from the first location to a second location a predetermined distance away from the mold 124 of the rotor blade 16 via an automatic guided vehicle. Furthermore, in an embodiment, transporting the movable assembly fixture 100 adjacent to the mold 124 may include aligning the movable assembly fixture 100 at the predetermined distance with a rail system 134. moving the movable assembly fixture 100 adjacent to the mold 124 via the rail system 134.

[0039] Still referring to FIG. 8, as shown at (206), the method 200 includes aligning the blade root section 110 with the mold 124 via the movable assembly fixture 100. For example, in an embodiment, aligning the blade root section 110 with the mold 124 via the movable assembly fixture 100 may include aligning the blade root section 110 with the mold 124 via the alignment feature(s) 136, 138 of the movable assembly fixture 100. More specifically, as mentioned, the alignment feature(s) 136, 138 may include the first and second hook members 136. 138 on opposing sides of the movable assembly fixture 100 that align with corresponding hook members 140 of the mold 124.

[0040] As shown at (208), the method 200 includes vertically moving the blade root section 110 up or down via the movable assembly fixture 100 to precisely position the blade root section 110 atop the one or more fiber layers 125 in the mold 124 at a predetermined angle. More specifically, vertically moving the blade root section 110 up or dow n via the movable assembly fixture 100 to precisely position the blade root section 110 atop the fiber layer(s) 125 in the mold 124 at thepredetermined angle may include lifting the blade root section 110 via the movable assembly fixture 100 above the fiber layer(s) 125 and lowering the blade root section 11 via the movable assembly fixture 100 atop the fiber lay efts) 125 at the predetermined angle.

[0041] Further, as shown at (210), the method 200 includes securing (e.g., via mounting and / or torquing) the root plate 108 having the blade root section 110 secured thereto to the mold 124. Moreover, as shown at (212). the method 200 includes applying a core material after mounting and torquing the root plate 108 to the mold 124. After applying the core material, one or more additional fiber layers can be placed atop the core material. Thus, as shown at (214), the method 200 includes infusing the blade root section 110, the core material, and the fiber layer(s) 125 together with a resin matrix to form the rotor blade 16. In such embodiments, the resin matrix may include, for example, polyester, vinyl ester, epoxy matrix, or any other suitable resin matrix.

[0042] Further aspects of the invention are provided by the disclosure of the following clauses:

[0043] A method for assembling a rotor blade, the method comprising: securing a blade root section of the rotor blade to a movable assembly fixture, the movable assembly fixture having a counterbalance for stabilizing the blade root section in the movable assembly fixture; transporting the movable assembly fixture adjacent to a mold of the rotor blade, the mold having one or more fiber layers placed therein; aligning the blade root section with the mold via the movable assembly fixture; vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at a predetermined angle; and infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

[0044] The method of any preceding clause, further comprising forming the blade root section of the rotor blade in an assembly jig at a first location, the assembly jig configured to support a root plate, the blade root section being formed on and secured to the root plate.

[0045] The method of any preceding clause, wherein securing the blade rootsection of the rotor blade to the movable assembly fixture further comprises securing the root plate having the blade root section formed on and secured thereto to the movable assembly fixture.

[0046] The method of any preceding clause, further comprising: securing the root plate having the blade root section secured thereto to the mold; applying a core material in the mold after securing the root plate to the mold: and applying one or more additional fiber layers atop the core material before infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

[0047] The method of any preceding clause, wherein the movable assembly fixture further comprises first and second arm members for securing the root plate thereto.

[0048] The method of any preceding clause, wherein the movable assembly fixture further comprises a plurality of rollers for allowing movement thereof.

[0049] The method of any preceding clause, wherein transporting the movable assembly fixture adjacent to the mold of the rotor blade further comprises rolling the movable assembly fixture from the first location to a second location a predetermined distance away from the mold of the rotor blade via an automatic guided vehicle.

[0050] The method of any preceding clause, wherein transporting the movable assembly fixture adjacent to the mold of the rotor blade further comprises:

[0051] aligning the movable assembly fixture at the predetermined distance with a rail system; and moving the movable assembly fixture adjacent to the mold via the rail system.

[0052] The method of any preceding clause, wherein aligning the blade root section with the mold via the movable assembly fixture further comprises:

[0053] aligning the blade root section with the mold via one or more alignment features of the movable assembly fixture.

[0054] The method of any preceding clause, wherein the one or more alignment features comprise a first hook member and a second hook member on opposing sides of the movable assembly fixture that align with corresponding hook members of the mold.

[0055] The method of any preceding clause, wherein vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at the predetermined angle further comprises: lifting the blade root section via the movable assembly fixture above the one or more fiber layers; and lowering the blade root section via the movable assembly fixture atop the one or more fiber layers at the predetermined angle.

[0056] The method of any preceding clause, wherein the movable assembly fixture further comprises a lifting assembly for lifting and lowering the blade root section, the lifting assembly comprising at least one of a hydraulic system, an actuator system, or a lift.

[0057] The method of any preceding clause, further comprising supporting the first and second arm members via first and second support members, respectively, of the lifting assembly .

[0058] A movable assembly fixture for assembling a rotor blade, the assembly fixture comprising: a frame structure; one or more arm members for receiving a root plate, the root plate configured to secure a blade root section on a first side of the frame structure; a counterbalance mounted on a second side of the frame structure for balancing a weight of the blade root section; a plurality of rollers mounted to a bottom side of the frame structure for allowing movement of the movable assembly fixture; and a lifting assembly for lifting and lowering the blade root section onto a mold of the rotor blade at a predetermined angle atop one or more fiber lay ers in the mold.

[0059] The movable assembly fixture of any preceding clause, further comprising an automatic guided vehicle for transporting the movable assembly fixture adjacent to the mold of the rotor blade by engaging the plurality of rollers.

[0060] The movable assembly fixture of any preceding clause, wherein the one or more arm members comprise first and second arm members, the root plate comprises first and second through holes sized to receive the first and second arm members.

[0061] The movable assembly fixture of any preceding clause, wherein the lifting assembly further comprises first and second support members supporting thefirst and second arm members.

[0062] The movable assembly fixture of any preceding clause, further comprising a rail system for aligning the movable assembly fixture adjacent to the mold.

[0063] The movable assembly fixture of any preceding clause, further comprising one or more alignment features for aligning the blade root section with the mold, wherein the one or more alignment features comprise a first hook member and a second hook member on opposing sides of the movable assembly fixture that align with corresponding hook members of the mold.

[0064] The movable assembly fixture of any preceding clause, wherein the lifting assembly comprises at least one of a hydraulic system, an actuator system, or a lift.

[0065] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated 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. Such 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 with insubstantial differences from the literal language of the claims.

Claims

WHAT IS CLAIMED IS:

1. A method for assembling a rotor blade, the method comprising: securing a blade root section of the rotor blade to a movable assembly fixture, the movable assembly fixture having a counterbalance for stabilizing the blade root section in the movable assembly fixture; transporting the movable assembly fixture adjacent to a mold of the rotor blade, the mold having one or more fiber layers placed therein; aligning the blade root section with the mold via the movable assembly fixture; vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at a predetermined angle; and infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

2. The method of claim 1, further comprising forming the blade root section of the rotor blade in an assembly jig at a first location, the assembly jig configured to support a root plate, the blade root section being formed on and secured to the root plate.

3. The method of claim 2, wherein securing the blade root section of the rotor blade to the movable assembly fixture further comprises securing the root plate having the blade root section formed on and secured thereto to the movable assembly fixture.

4. The method of claim 3, further comprising: securing the root plate having the blade root section secured thereto to the mold; applying a core material in the mold after securing the root plate to the mold; and applying one or more additional fiber layers atop the core material before infusing the blade root section and the one or more fiber layers together with a resin material to form the rotor blade.

5. The method of claim 3, wherein the movable assembly fixture further comprises first and second arm members for securing the root plate thereto.

6. The method of claim 3, wherein the movable assembly fixture further comprises a plurality of rollers for allowing movement thereof.

7. The method of claim 6. wherein transporting the movable assembly fixture adjacent to the mold of the rotor blade further comprises rolling the movable assembly fixture from the first location to a second location a predetermined distance away from the mold of the rotor blade via an automatic guided vehicle.

8. The method of claim 7. wherein transporting the movable assembly fixture adjacent to the mold of the rotor blade further comprises: aligning the movable assembly fixture at the predetermined distance with a rail system; and moving the movable assembly fixture adjacent to the mold via the rail system.

9. The method of claim 1, wherein aligning the blade root section with the mold via the movable assembly fixture further comprises: aligning the blade root section with the mold via one or more alignment features of the movable assembly fixture.

10. The method of claim 9. wherein the one or more alignment features comprise a first hook member and a second hook member on opposing sides of the movable assembly fixture that align with corresponding hook members of the mold.

11. The method of claim 5, wherein vertically moving the blade root section up or down via the movable assembly fixture to precisely position the blade root section atop the one or more fiber layers in the mold at the predetermined angle further comprises: lifting the blade root section via the movable assembly fixture above the one or more fiber layers; and lowering the blade root section via the movable assembly fixture atop the one or more fiber layers at the predetermined angle.

12. The method of claim 11, wherein the movable assembly fixture further comprises a lifting assembly for lifting and lowering the blade root section, the lifting assembly comprising at least one of a hydraulic system, an actuator system, or a lift.

13. The method of claim 12, further comprising supporting the first and second arm members via first and second support members, respectively, of the lifting assembly.

14. A movable assembly fixture for assembling a rotor blade, the movable assembly fixture comprising: a frame structure: one or more arm members for receiving a root plate, the root plate configured to secure a blade root section on a first side of the frame structure; a counterbalance mounted on a second side of the frame structure for balancing a weight of the blade root section; a plurality of rollers mounted to a bottom side of the frame structure for allowing movement of the movable assembly fixture; and a lifting assembly for lifting and lowering the blade root section onto a mold of the rotor blade at a predetermined angle atop one or more fiber layers in the mold.

15. The movable assembly fixture of claim 14, further comprising an automatic guided vehicle for transporting the movable assembly fixture adjacent to the mold of the rotor blade by engaging the plurality' of rollers.

16. The movable assembly fixture of claim 14. wherein the one or more arm members comprise first and second arm members, the root plate comprises first and second through holes sized to receive the first and second arm members.

17. The movable assembly fixture of claim 15, wherein the lifting assembly further comprises first and second support members supporting the first and second arm members.

18. The movable assembly fixture of claim 14, further comprising a rail system for aligning the movable assembly fixture adjacent to the mold.

19. The movable assembly fixture of claim 14, further comprising one or more alignment features for aligning the blade root section with the mold, wherein the one or more alignment features comprise a first hook member and a second hook member on opposing sides of the movable assembly fixture that align with corresponding hook members of the mold.

20. The movable assembly fixture of claim 14. wherein the lifting assembly comprises at least one of a hydraulic system, an actuator system, or a lift.

Images