阅读说明：本技术 与增材制造构件互连的抗剪腹板组件 (Shear web assembly interconnected with an additive manufactured component ) 是由 D·罗伯茨 N·K·阿尔索夫 M·W·尼尔森 J·R·托宾 于 2019-03-25 设计创作，主要内容包括：本发明涉及一种用于组装风力涡轮机的抗剪腹板组件的方法,包括提供至少一个翼梁帽。该方法还包括经由增材制造形成热塑性材料的翼梁连接部件。此外,该方法包括将翼梁连接部件固定至翼梁帽。此外,该方法包括：提供抗剪腹板；经由增材制造形成热塑性材料的腹板连接部件；以及将腹板连接部件固定在抗剪腹板的第一端处。另外,该方法包括在接头处将腹板连接部件和翼梁连接部件互连。因此,该方法还包括加热接头以将腹板连接部件和翼梁连接部件固定在一起。(The present invention relates to a method for assembling a shear web assembly of a wind turbine, comprising providing at least one spar cap. The method also includes forming the spar connection components of thermoplastic material via additive manufacturing. Further, the method includes securing the spar connection member to the spar cap. Further, the method comprises: providing a shear web; forming a web connecting member of thermoplastic material via additive manufacturing; and securing the web connection member at the first end of the shear web. Additionally, the method includes interconnecting the web connection member and the spar connection member at a joint. Accordingly, the method further includes heating the joint to secure the web connection member and the spar connection member together.)

1. A method for assembling a rotor blade for a wind turbine, the method comprising:

forming a first spar connection member;

providing a shear web;

providing a first web connection component at a first end of the shear web, the first spar connection component and the first web connection component being formed from a thermoplastic material;

interconnecting the first web connection member and the first spar connection member at a first joint; and

heating the first joint to secure the first web connection member and the first spar connection member together.

2. The method of claim 1, further comprising:

forming a second spar connection component;

providing a second web connection component at an opposite second end of the shear web, the second spar connection component and the second web connection component being formed from a thermoplastic material;

interconnecting the second web connection member and the second spar connection member at a second joint; and

heating the second joint to secure the second web connection member and the second spar connection member together.

3. The method of claim 2, further comprising:

a lower shell member forming the rotor blade;

forming a second spar cap on the lower shell component, the second spar cap including the second spar connection component;

interconnecting the second web connection member and the second spar connection member at the second joint;

an upper shell part forming the rotor blade;

forming a first spar cap on the upper shell member, the first spar cap including the first spar connection component;

interconnecting the first web connection member and the first spar connection member at the first joint; and

Heating the first joint and the second joint.

4. The method of claim 2, further comprising forming the first and second web connection members via at least one of additive manufacturing, thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding, or a combination thereof.

5. The method of claim 4, further comprising forming the first and second spar connection components via at least one of additive manufacturing, thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding, or a combination thereof.

6. The method of claim 2, further comprising:

forming at least one of the first joint or the second joint via an ultrasonic signal transmitting material; and

inspecting at least one of the first joint or the second joint via non-destructive inspection (NDT) inspection.

7. The method of claim 2, further comprising securing the first and second web connection components to the first and second ends of the shear web, respectively, by at least one of pouring, inserting, interference fit, one or more adhesives, or one or more fasteners.

8. The method of claim 3, wherein forming the first and second spar caps that include the first and second spar connection components, respectively, further comprises:

co-infusing the first spar connection member with the first spar cap; and

co-pouring the second spar connection components with the second spar cap.

9. The method of claim 1, wherein the first and second spar connection components each comprise a female connector and the first and second web connection components each comprise a corresponding male connector.

10. The method of claim 2, further comprising providing a cover material on top of at least one of the first and second spar connection members or the first and second web connection members.

11. The method of claim 10, further comprising removing the cover material from at least one of the first and second spar connection members or the first and second web connection members prior to interconnecting the first and second web connection members with the first and second spar connection members.

12. The method of claim 10, further comprising placing a locating spacer on top of at least one of the first and second spar connection members to align at least one of the first and second web connection members.

13. The method of claim 1, further comprising reinforcing the thermoplastic material with at least one fibrous material.

14. A method for assembling a shear web assembly of a rotor blade of a wind turbine, the method comprising:

forming a spar connection component of thermoplastic material via additive manufacturing;

securing the spar connection member to the rotor blade;

providing a shear web;

forming a web connecting member made of a thermoplastic material via additive manufacturing;

securing the web connection member at a first end of the shear web;

interconnecting the web connection member and the spar connection member at a joint; and

the joints are secured together via at least one of thermal welding, chemical welding, resistance welding, solvent welding, one or more adhesives, or microwave heating.

15. A rotor blade assembly for a wind turbine, the rotor blade assembly comprising:

a rotor blade, comprising:

an upper shell member having a first spar cap configured on an inner face thereof;

a lower shell component having a second spar cap configured on an inner face thereof, the first and second spar caps comprising first and second spar connection components, respectively; and

a shear web extending between the first and second spar caps along a longitudinal length of the rotor blade, the shear web including first and second web connection members extending from opposite ends thereof, the first and second web connection members being received within the first and second spar connection members, respectively, to form first and second joints, the first and second spar connection members and the first and second web connection members each being formed from a thermoplastic material,

wherein the first web connection component and the second web connection component are retained within the first spar connection component and the second spar connection component via thermoplastic welding.

16. The rotor blade assembly of claim 15, wherein the first joint and the second joint are free of adhesive.

17. The rotor blade assembly of claim 15, wherein the first and second web connection members and the first and second spar connection members are formed via at least one of additive manufacturing, pultrusion, continuous molding, or extrusion molding.

18. The rotor blade assembly of claim 15, wherein the first and second spar connection members each comprise a female connector and the first and second web connection members each comprise a corresponding male connector.

19. The rotor blade assembly of claim 18, wherein the male connector further comprises opposing flanges that abut against the respective first and second spar caps.

20. The rotor blade assembly of claim 15, wherein the thermoplastic material is reinforced with at least one fibrous material.

Technical Field

The present invention relates generally to wind turbines, and more particularly to a shear web for a wind turbine interconnected with additive manufacturing components.

Background

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. Modern wind turbines typically include a tower, generator, gearbox, nacelle, and one or more rotor blades. Rotor blades are the primary elements that transform wind energy into electrical energy. The blades have the cross-sectional profile of an airfoil such that, during operation, air flows over the blades creating a pressure differential between the sides. Therefore, a lift force from the pressure side toward the suction side acts on the blade. The lift force generates torque on the main rotor shaft, which is geared to a generator gear for producing electrical power.

Rotor blades are typically constructed from a suction side shell and a pressure side shell that are bonded together at bond lines along the leading and trailing edges of the blade. An internal shear web extends between the pressure and suction side shell members and is bonded to a spar cap (spar cap) secured to the inner face of the shell members. In order for the shear web to span between the spar caps and achieve a bond between the spar caps and the shear web with sufficient width and thickness dimensions, a relatively precise length dimension is required. Achieving these dimensions and a proper bond can be difficult, and the joint between the spar caps and the shear web is a time consuming and tedious process, which typically requires a significant amount of rework.

For a typical blade construction, the shear web is a continuous member spanning between the spar caps, and the rigid flanges are used to achieve a desired bond width of bond paste (bond paste) applied between the spar caps and the transverse ends of the shear web. However, this configuration places significant stress on the joint between the shear web and the spar cap, and often results in the use of excess bond paste to achieve the desired bond width at this critical joint. However, excessive paste may cause unnecessary weight to the blade. In addition, excess extruded paste can break into fragments of cured paste that can rattle throughout the interior of the rotor blade during operation of the wind turbine (a not uncommon complaint from wind turbine owners/operators). Also, in typical configurations, the air gaps and unpredictable extrusion of bond paste can result in areas of reduced bond strength, which is particularly problematic in blade segments where repair from the interior of the rotor blade is not possible.

Accordingly, the industry would benefit from an improved joint between a shear web and a spar cap that addresses the above-mentioned problems.

Disclosure of Invention

Aspects and advantages of the invention will be set forth in, or will be apparent from, the description which follows, or may be learned by practice of the invention.

In one aspect, the present disclosure is directed to a method for assembling a rotor blade of a wind turbine. The method includes forming a first spar connection member. The method also includes providing a shear web. Further, the method includes providing a first web connection component at the first end of the shear web. The first spar connection members and the first web connection members are formed from a thermoplastic material. Thus, the method includes interconnecting the first web connection member and the first spar connection member at a first joint. Additionally, the method includes heating the first joint to secure the first web connection member and the first spar connection member together.

In one embodiment, the method may further include forming a second spar connection component made of a thermoplastic material, providing a second web connection component at an opposite second end of the shear web and also made of a thermoplastic material, interconnecting the second web connection component and the second spar connection component at a second joint, and heating the second joint to secure the second web connection component and the second spar connection component together.

In another embodiment, the method may include forming a lower shell component of the rotor blade; forming a second spar cap on the lower shell member, the second spar cap including a second spar connection component; interconnecting the second web connection member and the second spar connection member at a second joint; an upper shell member forming a rotor blade; forming a first spar cap on the upper shell member, the second spar cap including a second spar connection member; interconnecting the first web connection member and the first spar connection member at a first joint; and heating the first joint and the second joint.

In other embodiments, the method may include forming the first web attachment member and the second web attachment member via at least one of additive manufacturing, thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding (e.g., in several parts), or a combination thereof. Similarly, the method may include forming the first and second spar connection members via at least one of additive manufacturing, thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding, or a combination thereof.

In further embodiments, the method may include forming the first joint and/or the second joint via an ultrasonic signal transmitting material; and inspecting at least one of the first joint or the second joint via non-destructive inspection (NDT) inspection.

In several embodiments, the method may further comprise securing the first and second web connection members to the first and second ends of the shear web, respectively, by at least one of pouring, insertion/interference fit, adhesive, fastener, or a combination thereof.

In a particular embodiment, the step of forming first and second spar caps having first and second spar connection members may include co-pouring the first spar connection member with the first spar cap, and the second spar connection member with the second spar cap, respectively.

In certain embodiments, the first spar connection component and the second spar connection component may each include a female connector, while the first web connection component and the second web connection component may each include a corresponding male connector.

In still further embodiments, the method may further include providing a covering material on top of at least one of the first and second spar connection members or the first and second web connection members to protect the connection members from debris prior to interconnection. In such embodiments, the method may include removing the cover material from at least one of the first and second spar connection members or the first and second web connection members prior to interconnecting the first and second spar connection members and the second web connection members.

In further embodiments, the method may include placing a positioning spacer (positioning spacer) on top of at least one of the first and second spar connection members to align the at least one of the first and second web connection members. In yet another embodiment, the method may include reinforcing the thermoplastic material with at least one fibrous material.

In another aspect, the present disclosure is directed to a method for assembling a shear web assembly of a rotor blade of a wind turbine. The method includes forming a spar connection component of thermoplastic material via additive manufacturing. Further, the method includes securing the spar connection components to the rotor blade (e.g., to the blade shell and/or a structural member such as a spar cap). Further, the method comprises: providing a shear web; forming a web connecting member of thermoplastic material via additive manufacturing; and securing the web connection member at the first end of the shear web. Additionally, the method includes interconnecting the web connection member and the spar connection member at a joint. Accordingly, the method further includes securing the joints together via at least one of thermal welding, chemical welding, resistance welding, solvent welding, one or more adhesives, or microwave heating.

In yet another aspect, the present disclosure is directed to a rotor blade assembly for a wind turbine. The rotor blade assembly includes a rotor blade having: an upper shell member having a first spar cap configured on an inner face thereof; a lower shell component having a second spar cap configured on an inner face thereof, the first and second spar caps including first and second spar connection components, respectively; and a shear web extending along a longitudinal length of the rotor blade between the first spar cap and the second spar cap. The shear web includes first and second web connection members extending from opposite ends thereof. The first and second web connection members are received within the first and second spar connection members, respectively, to form first and second joints. Further, the first and second spar connection components and the first and second web connection components are each formed from a thermoplastic material. Thus, the first and second web connection members are retained within the first and second spar connection members via thermoplastic welding.

In one embodiment, the first joint and the second joint are free of adhesive. It should also be appreciated that the rotor blade assembly may include any other steps and/or features described herein.

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.

Drawings

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:

FIG. 1 illustrates a perspective view of a wind turbine according to the present disclosure;

FIG. 2 illustrates a perspective view of a rotor blade of a wind turbine according to the present disclosure;

FIG. 3 illustrates a cross-sectional view of one embodiment of a rotor blade assembly of a wind turbine according to the present disclosure, particularly illustrating a shear web constructed according to aspects of the present disclosure;

FIG. 4 illustrates an enlarged partial cross-sectional view of the rotor blade of FIG. 3;

FIG. 5 illustrates a flow diagram of one embodiment of a method for assembling a rotor blade assembly of a wind turbine according to the present disclosure;

FIG. 6 illustrates a partial cross-sectional view of one embodiment of a rotor blade assembly according to the present disclosure, particularly illustrating a covering material and a spacer positioned atop a spar cap connection member according to aspects of the present disclosure;

FIG. 7 illustrates a partial perspective view of one embodiment of a rotor blade assembly according to the present disclosure, particularly illustrating a spacer positioned atop a spar cap connection member according to aspects of the present disclosure; and

FIG. 8 illustrates a flow diagram of one embodiment of a method for assembling a shear web assembly of a wind turbine according to the present disclosure.

Detailed Description

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. Indeed, 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 one embodiment, can be used with another embodiment to yield a still further embodiment. It is therefore intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.

In general, the present subject matter relates to shear web assemblies constructed using thermoplastic glass fiber additive manufacturing processes. Thus, during component manufacturing, the additive component may be co-poured into one or more spar caps and/or one or more shear webs. The heating elements in the spar cap mold may then be heated to a sufficient temperature to allow the shear web additive components to melt/fuse together. Thus, using a heating element to join (i.e., melt/fuse) the connecting components together may help reduce current production cycle time. Alternatively, if there is a challenge in obtaining sufficient heat at the interface to thermally weld the thermoplastic interface, other embodiments include chemical welding of the interface (e.g., solvent welding), resistance welding using a metal mesh tape at the interface, adhesives, and/or microwave heating. In some cases, the thermoplastic glass transition temperature may be lower than the thermoplastic glass transition temperature of the blade shell resin to avoid charring/burning.

Such a feature helps to accurately position the shear web or webs on the spar cap. In addition, because these components allow one or more shear webs and one or more spar caps to be welded together, the use of adhesives may be reduced or eliminated, thereby reducing the cycle time for curing the adhesives. The additive components may also be used to help distribute loads between the one or more shear webs and the one or more spar caps.

Referring now to the drawings, FIG. 1 illustrates a wind turbine 10 according to the present disclosure. The wind turbine 10 includes a tower 12 with a nacelle 14 mounted thereon. A plurality of rotor blades 16 are mounted to a rotor hub 18, which in turn is 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 exemplary purposes only to place the present invention in an exemplary field of use. It should be appreciated that the present invention is not limited to any particular type of wind turbine configuration.

Referring now to FIG. 2, a more detailed view of the rotor blade assembly 15 according to the present disclosure is illustrated. As shown, the rotor blade assembly 15 includes one of the rotor blades 16 having an upper shell member 20 and a lower shell member 22. Further, the upper shell member 20 is configured as a suction side surface of the blade 16, and the lower shell member 22 is configured as a pressure side surface of the blade 16. The rotor blade 16 also includes a leading edge 24 and a trailing edge 26, as well as a root portion 28 and a tip portion 30. The upper shell member 20 and the lower shell member 22 may be joined together at a leading edge 24 and a trailing edge 26, as is well known in the art. The rotor blade 16 also includes an internal cavity 25 (FIG. 3) in which various structural components may be configured, such as one or more shear webs 40 and spar caps 32 according to the present disclosure.

Referring now to FIG. 3, a cross-sectional view of the rotor blade assembly 15 of FIG. 2 is illustrated that incorporates various aspects of the present disclosure. As shown, the rotor blade 16 includes at least one internal structural shear web 40 that spans between the upper and lower shell members 20,22 and extends along the longitudinal length of the rotor blade 16. In particular embodiments, as shown, the shear web 40 spans between the structural first and second spar caps 32,34 secured to the inner faces of the shell members 20, 22. Additionally, as shown in fig. 3 and 4, the first and second spar caps 32,34 also include first and second spar connection members 36, 38, respectively. Similarly, as shown, the shear web 40 includes first and second web connection members 46, 48 extending from opposite ends 42,44 thereof. Thus, as shown, the first and second web connection members 46, 48 are received within the first and second spar connection members 36, 38 to form first and second joints 50, 52, respectively. It should be understood that while the shear web 40 and spar caps 32,34 form a generally I-shaped web, other cross-sectional shapes are within the spirit and scope of the present invention, including, for example, an H-shaped web or a C-shaped web.

Additionally, the first and second spar connection components 36, 38 and the first and second web connection components 46, 48 are each formed from a thermoplastic material. Thus, in one embodiment, the first and second web connection components 46, 48 may be retained within the first and second spar connection components 38, 38 via thermoplastic welding. Thus, the first joint 50 and the second joint 52 may be adhesive free. Alternatively, some adhesive may be used to place the contours.

Referring to fig. 3 and 4, the first and second spar connection members 36, 38 may include female connectors 54. For example, as shown, the first and second spar connection members 36, 38 may include recesses. Additionally, as shown, the first and second web connection members 46, 48 may each include a corresponding male connector 56. For example, as shown, the first and second web connection members 46, 48 may include protrusions, ribs, or the like. Additionally, as shown, the male connector 56 may include opposing flanges 58 that abut against the respective first and second spar caps 32, 34. Accordingly, it should be understood that the male connector 56 may have any suitable cross-sectional shape. For example, as shown, the male connector 56 has a generally T-shaped cross-section. In further embodiments, the connecting member 65 may have an I-shaped cross-section or any other shape having the capability of functioning as described herein.

Further, in an alternative embodiment, it should be appreciated that first and second spar connection components 36, 38 may each include a male connector 56, while first and second web connection components 46, 48 may include a female connector 54.

The thermoplastic material used to form the first and second spar connection components 36, 38 and/or the first and second web connection components 46, 48 described herein generally comprises an essentially reversible plastic material or polymer. For example, thermoplastic materials typically become pliable or moldable when heated to a certain temperature and return to a more rigid state when cooled. Further, the thermoplastic material may comprise an amorphous thermoplastic material and/or a semi-crystalline thermoplastic material. For example, some amorphous thermoplastic materials may generally include, but are not limited to, styrene, vinyl, cellulosics, polyesters, acrylics, polysulfones, and/or imides. More specifically, exemplary amorphous thermoplastic materials may include polystyrene, Acrylonitrile Butadiene Styrene (ABS), polymethyl methacrylate, glycolide polyethylene terephthalate (PET-G), polycarbonate, polyvinyl acetate, amorphous polyamide, polyvinyl chloride (PVC), polyvinylidene chloride, polyurethane, or any other suitable amorphous thermoplastic material. Additionally, exemplary semi-crystalline thermoplastic materials may generally include, but are not limited to, polyolefins, polyamides, fluoropolymers, ethyl crotonates, polyesters, polycarbonates, and/or acetals. More specifically, exemplary semi-crystalline thermoplastic materials may include polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polypropylene, polyphenylene sulfide, polyethylene, polyamide (nylon), polyether ketone, or any other suitable semi-crystalline thermoplastic material.

Additionally, as noted above, the thermoplastic materials described herein can optionally be reinforced with fibrous materials including, but not limited to, glass fibers, carbon fibers, polymer fibers, wood fibers, bamboo fibers, ceramic fibers, nanofibers, metal fibers, or the like or combinations thereof. Additionally, the orientation of the fibers may include multi-axial, unidirectional, biaxial, triaxial, or any other suitable orientation and/or combination thereof. Further, the fiber content may vary depending on the stiffness required in the corresponding blade component, the area or location of the blade component in the rotor blade 16, and/or the desired weldability of the component. Further, the one or more fibrous materials may include continuous fibers and/or chopped fibers, such as in pultrusion.

Referring now to FIG. 5, a flow diagram of a method 100 for assembling a rotor blade 16 of a wind turbine 10 is shown. As shown at 102, the method 100 includes forming the first and second spar caps 32,34 with the first and second spar connection members 36, 38. For example, in certain embodiments, the first and second spar caps 32,34 may be co-poured with the first and second spar connection members 36, 38, respectively, during manufacturing. Alternatively, the first and second spar connection components 36, 38 may be formed as first and second spar caps 32,34, respectively, during the manufacturing process. In yet another embodiment, the first and second spar connection components 36, 38 may be formed as blade shells during the manufacturing process, rather than as spar caps 32, 34.

As shown at 104, the method 100 includes forming the first web connection member 46 and the second web connection member 48 via other techniques such as 3-D printing, additive manufacturing, automated fiber deposition, and depositing material with CNC control and multiple degrees of freedom. Additionally, the method 100 includes forming the first and second web attachment members 46,48 via thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding, or a combination thereof. Similarly, method 100 may include forming first and second spar connection members 36,38 via additive manufacturing, thermoforming, vacuum forming, pultrusion, continuous molding, extrusion molding, or a combination thereof. For example, in one embodiment, the method 100 may include forming the various connecting components 36,38,46,48 via thermoforming and additive manufacturing in the same process that provides a lamination surface using continuous fiber reinforcement in multiple directions (e.g., biaxial or triaxial) in a quick and efficient manner. More specifically, by thermoforming the shape of the web connection components 46,48 interfacing with the spar caps 32,34 and the one or more shear webs 40, the method 100 of the present disclosure may quickly create a desired joining surface for thermoplastic welding that can optionally be reinforced with a printed mesh structure as desired. Thus, alternatively or additionally, the method 100 may further include printing a grid structure in the area where the adhesive is used to join the components.

In embodiments utilizing pultrusion, the pultruded portion is designed to be sufficiently curved to conform to the pre-curved shape of the rotor blade 16. Thus, in certain embodiments, the pultrusion may be segments, optionally arranged with an adhesive between them, which will eventually melt together. In still further embodiments, the method 100 may include forming the first and second spar connection members 36, 38 and/or the first and second web connection members 46, 48 via continuous molding or extrusion molding.

Still referring to FIG. 5, as shown at 106, the method 100 includes securing the first and second web connection members 46, 48 at the first and second ends 42, 44, respectively, of the shear web 40. For example, in several embodiments, the method 100 may include securing the first and second web connection components 46, 48 to the first and second ends 42, 44, respectively, of the shear web 40 via potting, an insert/interference fit, an adhesive, a fastener, or a combination thereof. The various adhesives described herein may include, for example, glues, tapes, thermosetting resins, methacrylates, epoxies, vinyl esters, or any other suitable adhesive.

As mentioned, the first and second spar connection members 36, 38 and/or the first and second web connection members 46, 48 are formed from a thermoplastic material. As shown at 108, the method 100 includes interconnecting the first and second web connection members 46, 48 with the first and second spar connection members 36, 38 at the first and second joints 50, 52, respectively. Further, as shown at 110, the method 100 includes heating the first and second joints 50, 52 to secure the first and second web connection members 46, 36, 48, 38 together.

In another embodiment, method 100 may include forming a lower shell component 22 of a rotor blade 16, placing a second spar cap 34 onto the lower shell component 22, and interconnecting a first web connection component 46 and a first spar connection component 36 at a first joint 50. In such an embodiment, the method 100 further includes forming the upper shell member 20 of the rotor blade 16, placing the first spar cap 32 onto the upper shell member 20, and interconnecting the second web connecting member 48 and the second spar connecting member 38 at the second joint 52. Thus, as described above, the method 100 further includes heating the interconnected first and second joints 50, 52.

In further embodiments, the method may include forming one or more portions of the first joint 50 or the second joint 52 via an ultrasonic signal transmitting material. Accordingly, in such embodiments, the method 100 may include inspecting one or more portions of the first and second joints 50,52 via non-destructive inspection (NDT) inspection to check for defects in the joints 50, 52.

Referring now to FIG. 6, the method 100 may also include providing a cover material 60 on top of the first and second spar connection members 36, 38 and/or the first and second web connection members 46, 48 to protect the various connection members from debris (e.g., dirt or dust) prior to interconnection. Thus, the covering material 60 may function to keep the interface of the connecting members smooth for attachment. In such embodiments, the method 100 may include removing the cover material 60 from the associated connection component prior to interconnecting the male and female connection components together. In addition, the cover material 60 may be used for surface roughness (e.g., using a release layer having a particular texture), if desired. In such embodiments, the method 100 may include holding the cover material 60 in place to help interconnect the male and female connection components together. Thus, the cover material 60 may be used as a molded insert that is used to ensure placement and spacing of the first and second spar connection components 36, 38 prior to infusion.

Additionally, as shown in FIG. 7, the method 100 may include placing the locator spacer 62 on top of the first and second spar connection members 36, 38 to align at least one of the first and second web connection members 46, 48. In such embodiments, one or more spacers 62 may be located on top of the cover material 60, as shown.

Referring now to FIG. 8, a flow diagram of another embodiment of a method 200 for assembling a shear web assembly of a wind turbine 10 is shown. As shown at 202, the method 200 includes providing at least one spar cap (e.g., the first spar cap 32). As shown at 204, the method 200 includes forming a spar connection component (e.g., the first spar connection component 36) made of a thermoplastic material via additive manufacturing. As shown at 206, method 200 includes securing spar connection member 36 to spar cap 32. As shown at 208, the method 200 includes providing a shear web, such as the shear web 40. As shown at 210, method 200 includes forming a web connection member (e.g., first web connection member 46) made of a thermoplastic material via additive manufacturing. As shown at 212, the method 200 includes securing the web connection component 46 at a first end of the shear web 40. As shown at 214, method 200 includes interconnecting web attachment member 46 and spar attachment member 36 at joint 50. As shown at 216, the method 200 includes securing the joints together via at least one of thermal welding, chemical welding, resistance welding, adhesives, solvent welding, or microwave heating. More specifically, resistance welding may use a metal mesh strip at the interface. Additionally, for resistance welding, it may be important to connect the mesh tape to a down conductor which is also typically located on the shear web 40.

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 languages of the claims.