Patent Description:
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 modern wind turbine typically includes a tower, generator, gearbox, nacelle, and one or more turbine blades. The turbine blades capture kinetic energy from wind using known foil principles and transmit the kinetic energy through rotational energy 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.

To ensure that wind power remains a viable energy source, efforts have been made to increase energy outputs by modifying the size and capacity of wind turbines. One such modification has been to increase the length of the rotor blades. However, as is generally known, the deflection of a rotor blade is a function of blade length, along with wind speed, turbine operating states and blade stiffness. Thus, longer rotor blades may be subject to increased deflection forces, particularly when a wind turbine is operating in high-speed wind conditions. These increased deflection forces not only produce fatigue on the rotor blades and other wind turbine components but may also increase the risk of the rotor blades striking the tower.

In order to increase the length of wind turbine rotor blades without adversely affecting the aerodynamic design, a blade insert can be used to increase the span of a rotor blade by an amount generally corresponding to the overall length of the blade insert. In addition, improved methods for installing shear web inserts between the blade insert and an adjacent segment of the rotor blade are being developed for rotor blades that generally include a suction side shell and a pressure side shell and are typically formed using molding processes that are bonded together at bond lines along the leading and trailing edges of the blade. The pressure and suction shells are relatively lightweight and have structural properties (e.g., stiffness, buckling resistance and strength) which are not configured to withstand the bending moments and other loads exerted on the rotor blade during operation. Thus, to increase the stiffness, buckling resistance and strength of the rotor blade, the body shell is typically reinforced using one or more structural components (e.g. opposing spar caps with a shear web insert configured therebetween) that engage the inner pressure and suction side surfaces of the shell halves.

Such rotor blades, however, are not without issues. One particular issue that has arisen involves the connection of shear clips and shear web inserts and clips in rotor blade extensions. Shear clips have been typically utilized to reinforce the interface between the shear web and spar caps, and are connected to both such components at the shear web - spar cap interface. Because thermoset resins are generally utilized to form such rotor blades, thermoset-based joining techniques such as the application of bonding pastes or hand lay-ups must be utilized to attach the shear clips to the shear web inserts and spar caps. It can thus be difficult and time-consuming to join shear clips and shear web inserts in rotor blades. Further, in many cases, the shear clips and shear web inserts may not completely align with the neighboring shear web and/or spar cap surfaces thereby forming an offset or misalignment. These misalignments occur outside of manufacturing tolerances when connecting the shear web and spar caps. Accordingly, the resulting joints may be sub-optimal. <CIT> and <CIT> are relevant examples of prior art.

Accordingly, improved methods for connecting and repairing shear web inserts in wind turbine rotor blades, including modular blades, would be advantageous.

In one aspect, a method is disclosed according to independent claim <NUM> for connecting and repairing a shear web, the method comprising:dry-fitting a shear web insert in a rotor blade assembly to establish a perimeter gap at an angled perimeter interface between the shear web insert and at least one adjacent surface selected from a first shear web, a second shear web, a first side of the rotor blade assembly, and a second side of the rotor blade assembly, and, injecting a bonding paste into the perimeter gap.

In another non claimed aspect, a rotor blade assembly for a wind turbine is disclosed as having a first side and a second side, wherein the first side of the rotor blade assembly corresponds to one of a pressure side or a suction side of the rotor blade assembly, and an opposite second side of the rotor blade assembly corresponds to the other pressure side or suction side of the rotor blade assembly. The rotor blade assembly further has a first blade segment defining a joint end, the first blade segment including a first shear web with an angled interface at the joint end, and a second blade segment coupled to the joint end of the first blade segment, the second blade segment including a second shear web with an angled interface at the joint end. At least one first connecting device is coupled across at least a portion of the joint end, the at least one first connecting device is coupled at least partially on the first side face of at least one of the first shear web and the second shear web. At least one second connecting device is coupled across at least a portion of the joint end, the at least one second connecting device coupled at least partially on the opposing second side face of at least one of the first shear web and the second shear web. Bonding paste is injected into the angled interface.

In another aspect, a connecting device for a rotor blade assembly of a wind turbine is disclosed according to independent claim <NUM>, the connecting device comprising; at least two pre-fabricated clips further comprising horizontal and vertical portions, the horizontal portion of a first of the at least two pre-fabricated clips is configured to be coupled to an inner surface of a first side of the rotor blade assembly and the horizontal portion of a second of the at least two pre-fabricated clips is configured to be coupled to an inner surface of a second side of the rotor blade assembly, wherein the vertical portions of the first and second of the at least two pre-fabricated clips extend from the respective horizontal portions in opposing directions a sufficient distance to couple with an opposing vertical portion.

In general, the present subject matter is directed to methods and devices for installing a horizontal shear web insert between a blade segment and a blade insert of a rotor blade assembly. The methods described herein are not limited only to blade inserts but can be used for any blade joint involving a shear web, for example in assembling modular blades. Specifically, in several embodiments, the blade segment and the blade insert may each include a shear web extending longitudinally therein. Due to the configuration of the blade insert and/or the blade segment, a gap may be defined between the shear webs of such components. As a result, a shear web insert must be installed across the gap defined between the blade shear webs. As will be described below, the blade insert may, in several embodiments, include an elongated projection generally aligned with one of its spar caps that extends to the blade segment, thereby preventing the shear web insert from being installed vertically between the shear webs. Thus, in accordance with aspects of the present subject matter, the disclosed method may be utilized to install the shear web insert horizontally between the shear webs.

The horizontal shear web installation can be difficult and messy. The injection method and devices disclosed herein allows the shear web to be positioned in a horizontal fashion without using bond paste to hold position but using spacers instead. Then once positioned, bond paste is injected into a perimeter gap to complete the joint. The shear web insert can be tapered to form an angled interface cut around the interface to allow proper flow of the bond paste. Without the proper angled interface, the bond paste would either not flow to the other side properly (if gap was too small) or allow too much bond paste flow to the other side (if gap is too large). The horizontal shear web insert installation method and devices disclosed herein can use at least one connecting device, such as a two-piece c-clip, at the joint between the blade shear webs and the shear web insert as a shear clip. This was previously done with a laminated connection having a separate pre-cure cycle step in between. The two piece c-clip connecting device, or shear clip, disclosed herein allows installation of a prefabricated c-clip without requiring a pre-cure step and also does not require additional sanding and prep before installation. The two-piece c-clip can be overlapped thereby allowing a generically sized c-clip to be installed in blades with varying dimensions due to tolerances and does not need to be pre-sized ahead of time. The c-clip can also be tapered in multiple areas to reduce stress concentrations. The injection method and devices disclosed herein can eliminate a pre-cure cycle, reduce cycle time, reduce messiness, and provide a better joint while eliminating previous paste application issues.

Referring now to the drawings, <FIG> illustrates a perspective view of one embodiment of a wind turbine <NUM>. As shown, the wind turbine <NUM> generally includes a tower <NUM> extending from a support surface <NUM>, a nacelle <NUM> mounted on the tower <NUM>, and a rotor <NUM> coupled to the nacelle <NUM>. The rotor <NUM> includes a rotatable hub <NUM> and at least one rotor blade <NUM> coupled to and extending outwardly from the hub <NUM>. For example, in the illustrated embodiment, the rotor <NUM> includes three rotor blades <NUM>. However, in an alternative embodiment, the rotor <NUM> may include more or less than three rotor blades <NUM>. Each rotor blade <NUM> may be spaced about the hub <NUM> to facilitate rotating the rotor <NUM> to enable kinetic energy to be transferred from the wind into usable mechanical energy, and subsequently, electrical energy. For instance, the hub <NUM> may be rotatably coupled to an electric generator (not shown) positioned within the nacelle <NUM> to permit electrical energy to be produced.

Referring now to <FIG>, a perspective view of one of the rotor blades <NUM> shown in <FIG> is illustrated. As shown, the rotor blade <NUM> generally includes a blade root <NUM> configured for mounting the rotor blade <NUM> to the hub <NUM> of the wind turbine <NUM> (<FIG>) and a blade tip <NUM> disposed opposite the blade root <NUM>. A body <NUM> of the rotor blade <NUM> may generally be configured to extend between the blade root <NUM> and the blade tip <NUM> and may serve as the outer casing/skin of the blade <NUM>. In several embodiments, the body <NUM> may define a substantially aerodynamic profile, such as by defining a symmetrical or cambered airfoil-shaped cross-section. As such, the body <NUM> may include a pressure side <NUM> and a suction side <NUM> extending between a leading edge <NUM> and a trailing edge <NUM>. Further, the rotor blade <NUM> may have a span <NUM> defining the total length between the blade root <NUM> and the blade tip <NUM> and a chord <NUM> defining the total length between the leading edge <NUM> and the trailing edge <NUM>. As is generally understood, the chord <NUM> may vary in length with respect to the span <NUM> as the rotor blade <NUM> extends from the blade root <NUM> to the blade tip <NUM>.

In several embodiments, the body <NUM> of the rotor blade <NUM> may be formed as a single, unitary component. Alternatively, the body <NUM> may be formed from a plurality of shell components. For example, the body <NUM> may be manufactured from a first shell half generally defining the pressure side <NUM> of the rotor blade <NUM> and a second shell half generally defining the suction side <NUM> of the rotor blade <NUM>, with the shell halves being secured to one another at the leading and trailing edges <NUM>, <NUM> of the blade <NUM>. Additionally, the body <NUM> may generally be formed from any suitable material. For instance, in one embodiment, the body <NUM> may be formed entirely from a laminate composite material, such as a carbon fiber reinforced laminate composite or a glass fiber reinforced laminate composite. Alternatively, one or more portions of the body <NUM> may be configured as a layered construction and may include a core material <NUM> (e.g., as shown in <FIG>), formed from a lightweight material such as wood (e.g., balsa), foam (e.g., extruded polystyrene foam) or a combination of such materials, disposed between layers of laminate composite material.

It should be appreciated that the rotor blade <NUM> may also include one or more longitudinally extending structural components configured to provide increased stiffness, buckling resistance and/or strength to the rotor blade <NUM>. For example, in several embodiments, the rotor blade <NUM> may include a pair of spar caps (e.g., a top spar cap <NUM> and a bottom spar cap <NUM>) and one or more shear webs <NUM>, <NUM> extending between the opposed spar caps <NUM>, <NUM> (e.g., as shown in <FIG>).

Referring now to <FIG>, one embodiment of a rotor blade assembly <NUM> is illustrated in accordance with aspects of the present subject matter. As shown, the rotor blade assembly <NUM> may include a first blade segment <NUM>, a second blade segment <NUM> and a blade insert <NUM> configured to be coupled between the first and second blade segments <NUM>, <NUM>. In general, the rotor blade assembly <NUM> may be configured such that, when the first and second blade segments <NUM>, <NUM> are coupled together via the blade insert <NUM>, a complete rotor blade is formed.

In several embodiments, the first and second blade segments <NUM>, <NUM> may be formed by dividing a pre-existing rotor blade <NUM> into two separate blade sections. For example, as shown in <FIG>, in one embodiment, the illustrated rotor blade <NUM> may be divided into the first and second blade segments <NUM>, <NUM> by cutting the rotor blade <NUM> along a joint or cut line <NUM>. Thus, in the illustrated embodiment, the first blade segment <NUM> may correspond to a root segment of the rotor blade <NUM> and may extend between the blade root <NUM> and a first joint end <NUM> formed at the cut line <NUM>. Similarly, in the illustrated embodiment, the second blade segment <NUM> may correspond a tip segment of the rotor blade <NUM> and may extend between the blade tip <NUM> and a second joint end <NUM> formed at the cut line <NUM>.

It should be appreciated that, although the first blade segment <NUM> is shown as a root segment and the second blade segment <NUM> is shown as a tip segment, the terms "first blade segment" and "second blade segment" may generally refer to any suitable segments or sections of the rotor blade <NUM>. For example, in another embodiment, the first blade segment <NUM> may correspond to a tip segment of the rotor blade <NUM> and the second blade segment <NUM> may correspond to a root segment of the rotor blade <NUM>. In a further embodiment, the first and second blade segments <NUM>, <NUM> may correspond to shorter segments of the rotor blade <NUM>.

Additionally, it should be appreciated that, as used herein, the terms "first blade segment" and "second blade segment" need not be limited to a single, continuous blade segment. For example, in the illustrated embodiment, the first blade segment <NUM> may be formed from a single, unitary blade segment extending between the blade root <NUM> and the first joint end <NUM> or the first blade segment <NUM> may be formed from two or more blade segments that, when coupled together, extend between blade root <NUM> and the first joint end <NUM>. Similarly, in the illustrated embodiment, the second blade segment <NUM> may be formed from a single, unitary blade segment extending between the second joint end <NUM> and the blade tip <NUM> or the second blade segment <NUM> may be formed from two or more blade segments that, when coupled together, extend between the second joint end <NUM> and the blade tip <NUM>.

Moreover, it should be appreciated that the cut line <NUM> (<FIG>) may generally be located at any suitable position along the span <NUM> of the rotor blade <NUM>. For example, in one embodiment, the distance of the cut line <NUM> from the blade root <NUM> may range from about <NUM>% to about <NUM>% of the span <NUM>, such as from about <NUM>% to about <NUM>% of the span <NUM> or from about <NUM>% to about <NUM>% of the span <NUM>. However, it is foreseeable that, in other embodiments, the distance of the cut line <NUM> from the blade root <NUM> may be less than <NUM>% of the span <NUM> or greater than <NUM>% of the span <NUM>.

It should also be appreciated that, in alternative embodiments, the first and second blade segments <NUM>, <NUM> need not be formed by cutting or otherwise dividing a pre-existing rotor blade <NUM> into two separate blade sections. For example, in another embodiment, the first and second blade segments <NUM>, <NUM> may be separately manufactured as modular blades and assembled together with the blade insert <NUM> to form the disclosed rotor blade assembly <NUM>.

Referring still to <FIG>, the blade insert <NUM> of the rotor blade assembly <NUM> may generally comprise an elongated, aerodynamic body <NUM> extending between a forward end <NUM> and an aft end <NUM>, thereby forming a separate blade segment of the rotor blade assembly <NUM>. In general, the blade insert <NUM> may be configured to be coupled between the first and second blade segments <NUM>, <NUM> in order to form the rotor blade assembly <NUM>. Specifically, the forward end <NUM> of the blade insert <NUM> may be configured to be coupled to the joint end <NUM> of the first blade segment <NUM>, and the aft end <NUM> of the blade insert <NUM> may be configured to be coupled to the joint end <NUM> of the second blade segment <NUM>. Suitable configurations and methods for attaching the blade insert <NUM> between the first and second blade segments <NUM>, <NUM> will generally be described below with reference to <FIG>.

Referring now to <FIG>, one embodiment of a particular blade insert/segment configuration that may be used to effectively and efficiently secure a blade insert <NUM> between first and second blade segments <NUM>, <NUM> of a rotor blade assembly <NUM> is illustrated in accordance with aspects of the present subject matter. Specifically, <FIG> illustrates a perspective view of the blade insert <NUM> and <FIG> illustrates a partial, cross-sectional view of the blade insert <NUM> shown in <FIG> taken about line <NUM>-<NUM>. Additionally, <FIG> illustrates a perspective view of a corresponding configuration that may be used for the first blade segment <NUM> and/or the second blade segment <NUM>.

As indicated above, the blade insert <NUM> may generally include an elongated body <NUM> extending between a forward end <NUM> and an aft end <NUM>, with the forward end <NUM> configured to be coupled to the joint end <NUM> of the first blade segment <NUM> and the aft end <NUM> being configured to be coupled to the joint end <NUM> of the second blade segment <NUM>. In general, the body <NUM> may be configured to define a substantially aerodynamic profile, such as by defining a symmetric or cambered airfoil-shaped cross-section. Thus, as shown in <FIG> and <FIG>, the body <NUM> may include a top side <NUM> (e.g., a pressure side) and a bottom side <NUM> (e.g., suction side) extending between a leading edge <NUM> and a trailing edge <NUM>. Additionally, as shown, the top side <NUM> of the body <NUM> may be configured to extend spanwise between a forward edge <NUM> disposed at the forward end <NUM> of the blade insert <NUM>) and an aft edge <NUM> disposed at the aft end <NUM> of the blade insert <NUM>. Similarly, the bottom side <NUM> of the body <NUM> may be configured to extend spanwise between a forward edge <NUM> (disposed at the forward end <NUM> of the blade insert <NUM> and an aft edge <NUM> disposed at the aft end <NUM> of the blade insert <NUM>.

The blade insert <NUM> may also include the same or similar internal structural components as the first and second blade segments <NUM>, <NUM>. For example, as shown in <FIG>, the blade insert <NUM> may include a pair of longitudinally extending spar caps (e.g., a top spar cap <NUM> and a bottom spar cap <NUM>), with each spar cap <NUM>, <NUM> being integrated into and/or forming part of either the top side <NUM> or the bottom side <NUM> of the blade insert <NUM>. In addition, the blade insert <NUM> may include one or more shear webs <NUM> (<FIG>) extending between the opposed spar caps <NUM>, <NUM>.

Additionally, in several embodiments, a portion of the top side <NUM> of the blade insert <NUM> may be recessed or offset from the forward and aft edges <NUM>, <NUM> of the bottom side <NUM> of the blade insert <NUM>. For example, as shown in <FIG>, portions of the top side <NUM> may be inwardly offset from the forward edge <NUM> of the bottom side <NUM> by a first spanwise distance <NUM> along either side of the top spar cap <NUM>, thereby defining separate offset portions of the forward edge <NUM> of the top side <NUM>. Similarly, portions of the top side <NUM> may also be inwardly offset from the aft edge <NUM> of the bottom side <NUM> by a second spanwise distance <NUM> along either side of the top spar cap <NUM>, thereby defining separate offset portions of the aft edge <NUM> of the top side <NUM>. As will be described below, by offsetting portions of the top side <NUM> as shown in <FIG>, separate access windows <NUM>, <NUM> (see <FIG>) may be defined at each end <NUM>, <NUM> of the blade insert <NUM> when the insert <NUM> is positioned between the first and second blade segments <NUM>, <NUM>. Such access windows <NUM>, <NUM> may generally allow for service workers to access the interior of the rotor blade assembly <NUM>, thereby allowing various components to be positioned within the assembly <NUM> to facilitate securing the blade insert <NUM> between the blade segments <NUM>, <NUM>. For example, as will be described below, a shear web insert <NUM> may be inserted through one of the access windows <NUM>, <NUM> and installed horizontally between the blade insert <NUM> and the blade segments <NUM>, <NUM> to couple the shear web of the blade segments <NUM>, <NUM> to the shear web insert <NUM> of the blade insert <NUM>.

It should be appreciated that the first and second spanwise distances <NUM>, <NUM> may generally correspond to any suitable distance. Additionally, in one embodiment, the first spanwise distance <NUM> may be equal to the second spanwise distance <NUM>. Alternatively, the first spanwise distance <NUM> may be greater or less than the second spanwise distance <NUM>.

It should also be appreciated that, as used herein, the terms "forward" and "aft" are simply used to distinguish the opposed ends <NUM>, <NUM> and/or edges <NUM>, <NUM>, <NUM>, <NUM> of the blade insert <NUM>. Thus, although the forward end <NUM> of the blade insert <NUM> is described herein as being configured to be coupled to the joint end <NUM> of the first blade segment <NUM>, the aft end <NUM> of the blade insert <NUM> may instead be configured to be coupled to the first blade segment <NUM>. Similarly, as used herein, the terms "top" and "bottom" are simply used to distinguish the opposed sides <NUM>, <NUM> of the blade insert <NUM>. For example, in the illustrated embodiment, the top side <NUM> of the blade insert <NUM> corresponds to the pressure side while the bottom side <NUM> corresponds to the suction side. However, in another embodiment, the top side <NUM> of the blade insert <NUM> may correspond to the suction side while the bottom side <NUM> may correspond to the pressure side.

Additionally, in several embodiments, a portion(s) of the top side <NUM> of the blade insert <NUM> may also be configured to extend beyond the forward and aft edges <NUM>, <NUM> of the bottom side <NUM> of the blade insert <NUM>. Specifically, as shown in <FIG> and <FIG>, elongated portions <NUM> of the top side <NUM> (generally aligned with the top spar cap <NUM>) may extend beyond the forward and aft edges <NUM>, <NUM> of the bottom side <NUM>, thereby defining extended portions of the forward and aft edges <NUM>, <NUM> of the top side <NUM>. As will be described below, such elongated portions <NUM> of the top side <NUM> may be configured to extend to a location at and/or adjacent to the joint ends <NUM>, <NUM> of the blade segments <NUM>, <NUM> when the blade insert <NUM> is positioned between the blade segments <NUM>, <NUM>.

Moreover, in several embodiments, one or more tapered or scarfed sections may be defined along the top and bottom sides <NUM>, <NUM> of the blade insert <NUM>. For example, as shown in <FIG>, first and second top scarfed sections <NUM>, <NUM> may be defined along the outer surface of the top side <NUM>, with the first top scarfed section <NUM> extending from an inner edge <NUM> to the forward edge <NUM> of the elongated portion <NUM> of the top side <NUM> and the second top scarfed section <NUM> extending from an inner edge <NUM> to the aft edge <NUM> of the elongated portion <NUM> of the top side <NUM>. Similarly, as shown in <FIG>, first and second bottom scarfed sections <NUM>, <NUM> may be defined along the inner surface of the bottom side <NUM>, with the first bottom scarfed section <NUM> extending from an inner edge <NUM> to the forward edge <NUM> of the bottom side <NUM> and the second top scarfed section <NUM> extending from an inner edge (not shown) to the aft edge <NUM> of the bottom side <NUM>. In such an embodiment, each scarfed section <NUM>, <NUM>, <NUM>, <NUM> may be configured to taper outwardly from its inner edge <NUM>, <NUM>, <NUM> (i.e., with the height of each scarfed section <NUM>, <NUM>, <NUM>, <NUM> increasing from its inner edge <NUM>, <NUM>, <NUM> to the respective forward or aft edges <NUM>, <NUM>, <NUM>, <NUM> of the top and bottom sides <NUM>, <NUM> of the blade insert <NUM>).

It should be appreciated that the scarfed sections <NUM>, <NUM>, <NUM>, <NUM> may generally be defined at any suitable chordwise location along the top and bottom sides <NUM>, <NUM> of the blade insert <NUM>. However, in several embodiments, the scarfed sections <NUM>, <NUM>, <NUM>, <NUM> may be aligned with the spar caps <NUM>, <NUM> of the blade insert <NUM>. For example, as shown in <FIG>, the top scarfed sections <NUM>, <NUM> are generally aligned with the top spar cap <NUM> while the bottom scarfed sections <NUM>, <NUM> are generally aligned with the bottom spar cap <NUM>. In such an embodiment, a width <NUM> (<FIG>) of each scarfed section <NUM>, <NUM>, <NUM>, <NUM> may generally correspond to the width of the spar caps <NUM>, <NUM>. Alternatively, the width <NUM> of each scarfed section <NUM>, <NUM>, <NUM>, <NUM> may be greater or less than the width of the spar caps <NUM>, <NUM>.

Moreover, a portion of the shell(s) forming the blade insert <NUM> may be recessed relative to the forward and aft edges <NUM>, <NUM>, <NUM>, <NUM> of the top and bottom sides <NUM>, <NUM>. For example, as shown in <FIG>, only an inner layer of the top side shell (e.g., one or more layers of laminate composite) may extend to the forward and aft edges <NUM>, <NUM> of the top side <NUM> while only an outer layer of the bottom side shell (e.g., one or more layers of laminate composite) may extend to the forward and aft edges <NUM>, <NUM> of the bottom side <NUM>, thereby defining top and bottom flanges <NUM>, <NUM> extending across portions of such edges <NUM>, <NUM>, <NUM>, <NUM>. As will be described below, the top and bottom flanges <NUM>, <NUM> may facilitate securing the blade insert <NUM> between the first and second blade segments <NUM>, <NUM>. The outer layers of the shell(s) (e.g., one or more outer layers of laminate composite and/or one or more layers of core material <NUM>) may then be positioned over the flanges <NUM>, <NUM> to create a smooth surface along the inner and outer surfaces of the rotor blade assembly <NUM>.

Referring now to <FIG>, a perspective view of a suitable segment configuration for attaching each blade segment <NUM>, <NUM> to the blade insert <NUM> shown in <FIG> and <FIG> is illustrated in accordance with aspects of the present subject matter. Specifically, <FIG> illustrates a perspective view of the joint end <NUM> of the first blade segment <NUM>. However, it should be appreciated that the joint end <NUM> of the second blade segment <NUM> may be configured the same as or similar to the joint end <NUM> shown in <FIG>.

As shown, the blade segment <NUM> may be modified to include scarfed sections <NUM>, <NUM> configured to be aligned with the scarfed sections <NUM>, <NUM> of the blade insert <NUM>. Specifically, in the illustrated embodiment, the blade segment <NUM> includes a top scarfed section <NUM> defined along the outer surface of its pressure side <NUM> that is configured to be aligned with top scarfed section <NUM> defined at the forward edge <NUM> of the top side <NUM> of the blade insert <NUM>. Similarly, the blade segment <NUM> includes a bottom scarfed section <NUM> defined along the inner surface of its suction side <NUM> that is configured to be aligned with the bottom scarfed section <NUM> defined at the forward edge <NUM> of the bottom side <NUM> of the blade insert <NUM>. As will be described below, a scarfed connector(s) may be positioned across each aligned pair of scarfed sections <NUM>, <NUM>, <NUM>, <NUM> to provide a means for securing the blade segment <NUM> to the blade insert <NUM>.

Additionally, similar to the blade insert <NUM>, the blade segment <NUM> may include an offset edge(s) <NUM> at its joint end <NUM> that is offset from the edge(s) of the opposing side of the blade segment <NUM> by a given spanwise distance <NUM>. Specifically, in the illustrated embodiment, a portion of the shell forming the pressure side <NUM> may be removed between the joint end <NUM> of the blade segment <NUM> and a front edge of the top scarfed section <NUM>, thereby defining the offset edge <NUM>. As will be described below, this removed portion of the shell may form part of the access window(s) <NUM>, <NUM> defined between the blade segment <NUM> and the blade insert <NUM> when such components are positioned adjacent to one another.

Moreover, as shown in <FIG>, a portion of the shell(s) forming the pressure and suction sides <NUM>, <NUM> of the blade segment <NUM> may be recessed relative to the joint end <NUM> of the blade segment <NUM>. For example, similar to the blade insert <NUM>, only an inner layer of the shell(s) (e.g., one or more layers of laminate composite) may be configured to extend to the joint end <NUM> of the blade segment <NUM>, thereby defining top and bottom flanges <NUM>, <NUM> around portions of the perimeter of the joint end <NUM>.

Referring now to <FIG>, several assembly views of the blade insert <NUM> shown in <FIG> and <FIG> and the blade segment <NUM> shown in <FIG> are illustrated in accordance with aspects of the present subject matter. Specifically, <FIG> illustrates a perspective view of the blade insert <NUM> and the blade segment <NUM> positioned end-to-end, with suitable components for securing the blade insert <NUM> to the blade segment <NUM> being exploded outward. <FIG> illustrates a perspective, assembled view of the various components shown in <FIG> and <FIG> illustrates a cross-sectional view of the assembly shown in <FIG> taken about line <NUM>-<NUM>.

As shown in <FIG>, when the blade segment <NUM> and the blade insert <NUM> are positioned end-to-end, separate access windows (e.g., a first access window <NUM> and a second access window <NUM>) may be defined between such components along either side of the elongated portion <NUM> of the top side <NUM> of the blade insert <NUM>. Such access windows <NUM>, <NUM> may generally allow a service worker(s) to access the interior of the rotor blade assembly <NUM>, thereby facilitating the installation of many of the assembly components shown in <FIG>. For example, in one embodiment, a bottom scarfed connector <NUM>, bottom shell inserts <NUM> and a shear web insert <NUM> may be installed within the rotor blade assembly <NUM> via the access provided by the access windows <NUM>, <NUM>. Thereafter, the access windows <NUM>, <NUM> may be covered by suitable window covers 184a, 184b to allow the assembly process to be finalized.

As indicated above, when the blade insert <NUM> and the blade segment <NUM> are positioned end-to-end, the bottom scarfed section <NUM> at the forward end <NUM> of the blade insert <NUM> may be configured to be aligned with the bottom scarfed section <NUM> of the blade segment <NUM>. Specifically, as shown in <FIG>, the aligned bottom scarfed sections <NUM>, <NUM> may be configured to abut one another when the blade insert <NUM> and blade segment <NUM> are positioned together. In such an embodiment, a bottom scarfed connector <NUM> may be positioned across the bottom scarfed sections <NUM>, <NUM> in order to facilitate coupling the blade insert <NUM> to the blade segment <NUM>. Specifically, as shown in <FIG> and <FIG>, the bottom scarfed connector <NUM> may generally define a tapered profile corresponding to the tapered profiles defined by the bottom scarfed sections <NUM>, <NUM>. Thus, as shown in <FIG>, the bottom scarfed connector <NUM> may be configured to extend across the interface defined between the blade segment <NUM> and the blade insert <NUM> so as to fill the open area defined by the bottom scarfed sections <NUM>, <NUM>.

In several embodiments, the bottom scarfed connector <NUM> may comprise a pre-fabricated component configured to be separately installed within the rotor blade assembly <NUM> (via one of the access windows <NUM>, <NUM>) and secured across the aligned bottom scarfed sections <NUM>, <NUM>, such as by securing the scarfed connector <NUM> within the bottom scarfed sections <NUM>, <NUM> using suitable bonding pastes, such as bonding pastes, and/or mechanical fasteners (e.g., bolts, screws, pins, rivets, brackets and/or the like). Alternatively, the bottom scarfed connector <NUM> may be formed or otherwise built-up within the aligned bottom scarfed sections <NUM>, <NUM>. For instance, in one embodiment, the scarfed connector <NUM> may be formed using a wet lay-up process, wherein a plurality of plies (including a reinforcement material such as glass or carbon fibers) are positioned across and/or within the bottom scarfed sections <NUM>, <NUM> and a resin or other suitable matrix material is rolled over or otherwise applied to the surface of the plies and allowed to cure.

In addition to the bottom scarfed sections <NUM>, <NUM>, the bottom flanges <NUM>, <NUM> of the blade insert <NUM> and the blade segment <NUM> may also be configured to abut one another when the blade insert <NUM> is positioned end-to-end with the blade segment <NUM>. As such, suitable bottom shell inserts <NUM> may be secured across the bottom flanges <NUM>, <NUM> along either side of the bottom scarfed connector <NUM> to further secure the blade insert <NUM> and the blade segment <NUM> to one another Specifically, the bottom shell inserts <NUM> may generally configured to extend across the interface defined between the blade segment <NUM> and the blade insert <NUM> so as to fill the open area defined by bottom flanges <NUM>, <NUM>. For example, as shown in <FIG>, the bottom shell inserts <NUM> may generally define a profile matching the profile of the corresponding portions of the shells for the blade insert <NUM> and the blade segment <NUM> and may also be formed from the same material (e.g., one or more layers of laminate component and/or one or more layers of core material <NUM>). It should be appreciated that, similar to the bottom scarfed connector <NUM>, the bottom shell inserts <NUM> may be pre-fabricated components or may be formed or otherwise built-up within the open area defined by the bottom flanges <NUM>, <NUM>.

As indicated above, a shear web insert <NUM> may also be installed within the rotor blade assembly <NUM> via one of the access windows <NUM>, <NUM>. As shown in <FIG>, the shear web insert <NUM> may generally include a first side face <NUM> and a second side face <NUM> extending between first and second ends <NUM>, <NUM>. In general, the shear web insert <NUM> may be configured to extend spanwise between the terminating ends of the shear webs <NUM>, <NUM> for the blade segment <NUM> and the blade insert <NUM>. Specifically, as shown in <FIG>, the shear web insert <NUM> may be configured to a define a length <NUM> between its first and second ends <NUM>, <NUM> generally corresponding to the gap defined between the end of the first shear web <NUM> for the blade segment <NUM> and the end of the second shear web <NUM> for the blade insert <NUM>. As such, the shear web insert <NUM> may be inserted within the rotor blade assembly <NUM> via one of the access windows <NUM>, <NUM> and subsequently secured between the shear webs <NUM>, <NUM>. For instance, as will be described below, one or more positioning device segments <NUM>, <NUM>, <NUM> and/or one or more connecting devices (<FIG>) may be coupled along the inner surfaces <NUM>, <NUM> of the first side <NUM> and second side <NUM> of the rotor blade assembly <NUM> (e.g., the inner surface <NUM> (<FIG>) defined along the pressure side or first side <NUM> of the assembly <NUM> and the inner surface <NUM> (<FIG>) defined along the suction side or second side <NUM> of the assembly <NUM>) to assist in installing the shear web insert <NUM> between the shear webs <NUM>, <NUM>.

After installing such components within the rotor blade assembly <NUM>, suitable window covers 184a, 184b may then installed between the blade insert <NUM> and the blade segment <NUM> so as to cover at least a portion of each access window <NUM>, <NUM>. For example, as shown in <FIG>, a first window cover 184a may be configured to extend across and/or cover at least a portion of the first access window <NUM>. Similarly, a second window cover 184b may be configured to extend across and/or cover at least a portion of the second access window <NUM>. As shown in <FIG>, the window covers 184a, 184b may generally have a similar construction to that of the shells used to form the blade insert <NUM> and the blade segment <NUM>. For example, the window covers 184a, 184b may be formed from a layered construction, including one or more layers laminate material and one or more layers of core material <NUM>.

Additionally, similar to the blade insert <NUM> and the blade segment <NUM>, a portion of the shell(s) forming the window covers 184a, 184b may be recessed or offset, thereby defining cover flanges <NUM> around the edges of the window covers 184a, 184b. Thus, when each window cover 184a, 214b is installed across its corresponding access window <NUM>, <NUM>, the cover flanges <NUM> may be configured to abut against the top flanges <NUM>, <NUM> of the blade insert <NUM> and the blade segment <NUM>. Thereafter, a suitable top shell insert <NUM> may be secured across each interface defined between the blade segment <NUM> and the window covers 184a, 184b and across each interface defined between the blade insert <NUM> and the window covers 184a, 184b so as to fill the open area defined by the top and cover flanges <NUM>, <NUM>, <NUM>. For example, as shown in <FIG>, the top shell inserts <NUM> may generally define a profile matching the profile of the corresponding portions of the shells for the blade insert <NUM> and the blade segment <NUM> and may also be formed from the same material (e.g., one or more layers of laminate component and/or one or more layers of core material <NUM>).

Moreover, as shown in the illustrated embodiment, the rotor blade assembly <NUM> may also include a top scarfed connector <NUM> configured to be positioned across the aligned top scarfed sections <NUM>, <NUM> of the blade insert <NUM> and the blade segment <NUM>. As shown in <FIG>, the top scarfed connector <NUM> may define a tapered profile corresponding to the tapered profiles defined by the top scarfed sections <NUM>, <NUM>. Thus, as particularly shown in <FIG>, the top scarfed connector <NUM> may be configured to extend across the interface defined between the blade segment <NUM> and the blade insert <NUM> so as to fill the area defined by the aligned top scarfed sections <NUM>, <NUM>.

It should be appreciated that, similar to the bottom scarfed connector <NUM> and the bottom shell inserts <NUM>, the top scarfed connector <NUM> and the tip shell inserts <NUM> may be pre-fabricated components or may be formed or otherwise built-up during assembly of the rotor blade assembly <NUM>.

It should also be appreciated that, after the various components of the rotor blade assembly <NUM> have been assembled between the blade segment <NUM> and the blade insert <NUM>, an overlaminate may be applied around the outer surface of the assembly <NUM> to ensure a smooth aerodynamic transition between the blade segment <NUM> and the blade insert <NUM>. For example, the overlaminate may be applied using a wet lay-up process, wherein one or more plies (including a reinforcement material such as glass or carbon fibers) are positioned along the outer surface and a resin or other suitable matrix material is rolled over or otherwise applied to the surface of the plies to form a smooth profile.

Moreover, it should be appreciated that, although the blade insert <NUM> was described with reference to <FIG> as simply being secured to one of the blade segments (e.g., the first blade segment <NUM>), the same or a similar methodology, as well as the same or similar components, may be used to secure the blade insert <NUM> to the other blade segment (e.g., the second blade segment <NUM>). For example, a bottom scarfed connector <NUM>, bottom shell inserts <NUM>, a shear web insert <NUM>, window cover(s) 184a, 184b, top shell inserts <NUM> and a top scarfed connector <NUM> may be installed between the aft end <NUM> of the blade insert <NUM> and the joint end <NUM> of the second blade segment <NUM> to allow such components to be secured to another in the same manner that the blade insert <NUM> and the first blade segment <NUM> were secured together (e.g., as shown in <FIG>).

Further, it should be appreciated that the blade insert <NUM> described herein may be considered as a blade segment. Thus, one of ordinary skill in the art should appreciate that the disclosed rotor blade assembly <NUM> may include one or a plurality of blade inserts <NUM>, with each blade insert forming an individual segment of the rotor blade assembly <NUM>.

Referring now to <FIG>, a flow diagram of one embodiment of a method <NUM> for installing a shear web insert <NUM> between the blade insert <NUM> and one of the blade segments <NUM>, <NUM> will be described in accordance with aspects of the present subject matter. In general, due to the configuration of the blade insert <NUM> (i.e., due to the elongated portions <NUM>), the shear web insert <NUM> must be installed horizontally. Specifically, the shear web <NUM> must be inserted through one of the access windows <NUM>, <NUM> and then inserted horizontally between the second shear web <NUM> for the blade insert <NUM> and the first shear web <NUM> for the corresponding blade segment <NUM>, <NUM>.

It should be appreciated that the method <NUM> will generally be described herein with reference to installing a shear web insert <NUM> between the blade insert <NUM> and the first blade segment <NUM>. However, the same methodology may also be utilized for installing a shear web insert <NUM> between the blade insert <NUM> and the second blade segment <NUM> or for assembling modular blades having a first shear web <NUM> and a second shear web <NUM>. For purposes of describing the disclosed method <NUM>, the shear web <NUM> of the first blade segment <NUM> will be referred to as a "first shear web <NUM>" and the shear web <NUM> of the blade insert <NUM> will be described as a "second shear web <NUM>. " Thus, a shear web insert <NUM> can be provided at both ends of the blade insert <NUM>, i.e. at both joints of the blade insert <NUM>. It should also be appreciated that, although method elements are presented in a particular order, the elements may generally be performed in any suitable order consistent with the disclosure provided herein.

As shown in <FIG>, a method <NUM> for connecting a blade segment <NUM> and blade insert <NUM> of a rotor blade assembly <NUM> at a shear web joint is disclosed, the blade segment <NUM> including a first shear web <NUM> and the blade insert <NUM> including a second shear web <NUM>. The method steps <NUM> through <NUM> include dry-fitting a shear web insert <NUM> in a rotor blade assembly <NUM> to establish a perimeter gap <NUM> at an angled perimeter interface <NUM> between the shear web insert <NUM> and the rotor blade assembly <NUM>, the angled perimeter interface <NUM> positioned between the shear web insert <NUM> and at least one adjacent surface of a first shear web <NUM>, a second shear web <NUM>, a first side of the rotor blade assembly <NUM>, and a second side of the rotor blade assembly <NUM>. Then injecting a bonding paste <NUM> into the perimeter gap <NUM>.

Additional method steps can include coupling at least one first connecting device (<NUM>) across a portion of the perimeter gap <NUM>, the at least one first connecting device <NUM> disposed partially on the first side face <NUM> of at least one of the first shear web <NUM> and the second shear web <NUM>, and then coupling at least one second connecting device <NUM> across a portion of the perimeter gap <NUM>, the at least one second connecting device <NUM> disposed partially on the opposing second side face <NUM> of at least one of the first shear web <NUM> and the second shear web <NUM>.

Also, the method can include coupling at least one first and second positioning device segments <NUM>, <NUM> along an inner surface <NUM>, <NUM> of at least one of a first side <NUM> or a second side <NUM> of the rotor blade assembly <NUM>. Then placing a plurality of spacers <NUM> along at least one of a bottom face <NUM>, a first end <NUM>, or a second end <NUM> of a shear web insert <NUM>, the plurality of spacers <NUM> aligned with a first side face <NUM> of the shear web insert <NUM>. Then positioning the shear web insert <NUM> between the first and second shear webs <NUM>, <NUM> until the first side face <NUM> of the shear web insert <NUM> engages the first and second positioning device segments <NUM>, <NUM>. The spacers <NUM> will thereby define a perimeter gap <NUM> around the shear web insert <NUM> angled perimeter interface <NUM>. Then injecting an bonding paste into the perimeter gap <NUM> around the shear web insert <NUM> angled perimeter interface <NUM>.

In general, the positioning device segments <NUM>, <NUM> may have any suitable configuration that allows such devices <NUM>, <NUM> to serve as mechanical stops for positioning the shear web insert <NUM> between the first and second shear webs <NUM>, <NUM>. As shown, in several embodiments, the positioning device segments <NUM>, <NUM> may each define an "L" shaped structural segment having a horizontal portion <NUM> coupled to the inner surface <NUM>, <NUM> of the assembly <NUM> (e.g., using a suitable bonding paste(s) or mechanical fastener(s)) and a vertical portion <NUM> extending generally perpendicularly from the horizontal portion <NUM>. In such an embodiment, the vertical portion <NUM> of each positioning device segment <NUM>, <NUM> may generally be configured to serve as a mechanical stop for the shear web insert <NUM> as it is being inserted between the first and second shear webs <NUM>, <NUM>. In other embodiments, the positioning device segments <NUM>, <NUM> may have any other suitable configuration that allows such devices to function as described herein.

Additionally, as shown in <FIG>, the first and second positioning device segments <NUM>, <NUM> may generally be configured to be aligned with one another in the horizontal or chordwise direction of the rotor blade assembly <NUM> (i.e., indicated by arrow <NUM>). Specifically, in several embodiments, the vertical portions <NUM> of the positioning device segments <NUM>, <NUM> may be aligned at a first chordwise position (indicated by the line <NUM> in <FIG>) that generally corresponds to the location at which the first side face <NUM> of the shear web insert <NUM> is to be positioned when the insert <NUM> is properly installed between the first and second shear webs <NUM>, <NUM>.

Moreover, in several embodiments, the positioning device segments <NUM>, <NUM> may be separately placed in the spanwise direction (indicated by arrow <NUM> in <FIG>) along all or a substantial portion of the length <NUM> of the shear web insert <NUM>. For example, as shown in <FIG>, the positioning device segments <NUM>, <NUM> can be separately placed along a length generally corresponding to the length <NUM> of the shear web insert <NUM>. Alternatively, the positioning device segments <NUM>, <NUM> may be separately placed to define a length that is shorter than the overall length <NUM> of the shear web insert <NUM>. In such an embodiment, a plurality of positioning device segments <NUM>, <NUM> may, for example, be spaced apart along the length <NUM> of the shear web insert <NUM>.

It should be appreciated that, in addition to acting as a mechanical stop, the positioning device segments <NUM>, <NUM> may also be used as a means for transferring loads through the rotor blade assembly <NUM>. For example, by coupling one or more positioning device segments <NUM>, <NUM> along the length <NUM> of the shear web insert <NUM>, loads may be transferred between the shear web insert <NUM> and the body <NUM> of the blade insert <NUM> and/or the body <NUM> of the blade segment <NUM>.

Referring back to <FIG>, at (<NUM>), the method <NUM> includes injecting an bonding paste <NUM> into the perimeter gap <NUM> around the shear web insert <NUM> angled perimeter interface <NUM> of the rotor blade assembly <NUM> at a location adjacent to the positioning device segment(s) <NUM>, <NUM>. Bonding paste injection can be performed by an injection device <NUM> such as a 'shoe' or injector nozzle. As the bonding paste <NUM> is injected, a volume of bonding paste <NUM> may be injected in a manner so that the bonding paste <NUM> extends from the vertical portions <NUM> of the positioning device segments <NUM>, <NUM> outward along the inner surfaces <NUM>, <NUM>. In injecting the bonding paste <NUM> along the inner surfaces <NUM>, <NUM>, it may be desirable to provide a sufficient amount of bonding paste <NUM> so that a squeeze out, or spill out occurs (e.g., as shown in <FIG>) at the interface between the positioning device segments <NUM>, <NUM> and the shear web insert <NUM> and the interface between the inner surfaces <NUM>, <NUM> and the shear web insert <NUM> when the insert <NUM> is positioned between the first and second shear webs <NUM>, <NUM>. As such, the bonding paste <NUM> may be uniformly spread between the shear web insert <NUM> and the positioning device segments <NUM>, <NUM> and between the shear web insert <NUM> and the inner surfaces <NUM>, <NUM> of the rotor blade assembly <NUM>.

It should be appreciated that any suitable bonding paste <NUM> known in the art may be utilized for securing the shear web insert <NUM> between the first and second shear webs <NUM>, <NUM>. In addition, it should be appreciated that the bonding paste <NUM> may be injected along the inner surfaces <NUM>, <NUM> of the rotor blade assembly <NUM> so as to form any suitable cross-sectional shape.

Referring back to <FIG>, at <NUM>, the method <NUM> includes positioning the shear web insert <NUM> between the first and second shear webs <NUM>, <NUM>. Specifically, in several embodiments, the shear web insert <NUM> may be inserted between the first and second shear webs <NUM>, <NUM> until the first side face <NUM> of the insert <NUM> engages the positioning device segments <NUM>, <NUM>, thereby indicating that the shear web insert <NUM> is properly positioned within the rotor blade assembly <NUM>. As used herein, the shear web insert <NUM> may be engaged with the positioning device segments <NUM>, <NUM> by contacting the devices <NUM>, <NUM> directly or by contacting the devices <NUM>, <NUM> indirectly (e.g., via the bonding paste <NUM>). For instance, as shown in <FIG>, the shear web insert <NUM> may be considered to be engaged with the positioning device segments <NUM>, <NUM> even though a layer of bonding paste <NUM> is present between the first side face <NUM> of the shear web insert <NUM> and the vertical portion <NUM> of each positioning device segment <NUM>, <NUM>.

As shown in <FIG>, when the shear web insert <NUM> is pushed horizontally into engagement with the positioning device segments <NUM>, <NUM>, the bonding paste <NUM> may be squeezed out, or spill out, from between the shear web insert <NUM>, the inner surfaces <NUM>, <NUM> and the positioning device segments <NUM>, <NUM>, thereby providing an indication that the bonding paste <NUM> has spread out between such components. In several embodiments, a top face <NUM> and/or a bottom face <NUM> of the shear web insert <NUM> may be shaped or otherwise configured to assist in allowing a proper squeeze out of the bonding paste <NUM>. For example, as particularly shown in the close up view of <FIG>, the top and bottom faces <NUM>, <NUM> may be angled relative to the inner surfaces <NUM>, <NUM> of the rotor blade assembly <NUM>. Specifically, the top and bottom faces <NUM>, <NUM> and the first and second ends <NUM>, <NUM> may include a perimeter gap <NUM> positioned around the angled perimeter interface <NUM> and may be angled away from the positioning device segments <NUM>, <NUM> so that a first gap <NUM> defined between the top and bottom faces <NUM>, <NUM> and the inner surfaces <NUM>, <NUM> at the first side face <NUM> of the shear web insert <NUM> is smaller than a second gap <NUM> defined between the top and bottom faces <NUM>, <NUM> and the inner surfaces <NUM>, <NUM> at the second side face <NUM> of the shear web insert <NUM>. For instance, in several embodiments, the top and bottom faces <NUM>, <NUM> may be configured to define an angle <NUM> relative to the inner surfaces <NUM>, <NUM> that ranges from about <NUM> degrees to about <NUM> degrees, such as from about <NUM> degrees to about <NUM> degrees or from about <NUM> degrees to about <NUM> degrees and any other subranges therebetween. By configuring the top and bottom faces <NUM>, <NUM> as shown in <FIG> and <FIG>, the bonding paste <NUM> may advantageously spread between the shear web insert <NUM> and the inner surfaces/positioning device segments <NUM>, <NUM>, <NUM>, <NUM> when the shear web insert <NUM> is properly positioned between the first and second shear webs <NUM>, <NUM>.

It should be appreciated that the gaps <NUM>, <NUM> defined between the shear web insert <NUM> and the inner surfaces <NUM>, <NUM> may generally correspond to any suitable distance. However, in several embodiments, the first gap <NUM> may generally range from about <NUM> millimeters (mm) to about <NUM>, such as from about <NUM> to about <NUM> or from about <NUM> to about <NUM> and any other subranges therebetween. Similarly, in several embodiments, the second gap <NUM> may generally range from <NUM> to about <NUM>, such as from <NUM> to about <NUM> or from about <NUM> to about <NUM> and any other subranges therebetween.

It should also be appreciated that, after positioning the shear web insert <NUM> between the first and second shear webs <NUM>, <NUM>, the insert <NUM> may be clamped or otherwise secured within the rotor blade assembly <NUM> to allow the bonding paste <NUM> to cure.

The method <NUM> can also include coupling at least one first connecting device <NUM> across a portion of the perimeter gap <NUM> defined between the first end <NUM> of the shear web insert <NUM> and the first shear web <NUM>, the first connecting device disposed on the second side face <NUM> of the shear web insert <NUM>. Then coupling a second connecting device <NUM> across a portion of the perimeter gap <NUM> defined between the first end <NUM> of the shear web insert <NUM> and the first shear web <NUM>, the second connecting device <NUM> disposed on the opposing first side face <NUM> of the shear web insert <NUM>.

Additional steps in method <NUM>, and illustrated in <FIG>, can include forming a shear web insert <NUM> angled perimeter interface <NUM> such that the perimeter gap <NUM> comprises a first gap <NUM> defined between the perimeter of the first side face <NUM> of the shear web insert <NUM> and an adjacent surface, and a second gap <NUM> is defined between the perimeter of the second side face <NUM> of the shear web insert <NUM> and an adjacent surface.

The perimeter gap <NUM> can be filled with bonding paste <NUM> using an injection device <NUM> as illustrated in <FIG>. The injection device <NUM> can be any suitable structure that can maintain contact with the perimeter gap <NUM> and allow continuous flow of the bonding paste, such as a 'shoe' or injector nozzle.

Further, as illustrated in <FIG>,each of the first and second connecting devices <NUM>, <NUM> can have first and second clips <NUM>, <NUM> further having horizontal and vertical portions <NUM>, <NUM>. The first clip <NUM> horizontal portion <NUM> can be coupled to the inner surface <NUM> of the first side <NUM> of the rotor blade assembly, and the second clip <NUM> horizontal portion <NUM> can be coupled to the inner surface <NUM> of the opposite second side <NUM> of the rotor blade assembly. The vertical portions <NUM> of the first and second clips <NUM>, <NUM> can extend from the horizontal portions <NUM>, in opposing directions, a sufficient distance such that the first and second clip vertical portions <NUM> overlap. Coupling of the horizontal portions <NUM> and vertical portions <NUM> of the first and second clips <NUM>, <NUM> can be accomplished using bonding paste <NUM>. Also, the first and second clips <NUM>, <NUM> can use tapered plies <NUM>. The first and second clips <NUM>, <NUM> can be constructed to control bond thickness and can be installed during the same cure cycle as the blade insert <NUM>.

Further, the connecting devices <NUM>, <NUM> can be coupled to the inner surface(s) <NUM>, <NUM> of the rotor blade assembly <NUM> so that the connecting devices <NUM>, <NUM> are positioned adjacent to and/or otherwise engage the first and second side faces <NUM>, <NUM> of the shear web insert <NUM> at any shear web joint. The connecting devices <NUM>, <NUM> may generally be configured to serve as means for retaining the shear web insert <NUM> within the rotor blade assembly <NUM>. In addition, the connecting devices <NUM>, <NUM> may also be configured to serve as a means for transferring loads between the shear web insert <NUM> and the body <NUM>, <NUM> of the rotor blade assembly <NUM> and/or the blade insert <NUM>.

It should be appreciated that the connecting devices <NUM>, <NUM> may generally have any suitable configuration that allows such device(s) <NUM>, <NUM> to function as described herein. For instance, the connecting devices <NUM>, <NUM> may be configured similarly to the positioning device segments <NUM>, <NUM> described above and, thus, may include a horizontal portion <NUM> configured to be coupled to the inner surfaces <NUM>, <NUM> (e.g., using a suitable bonding paste(s) or mechanical fastener(s)) and a vertical portion <NUM> extending generally perpendicularly from the horizontal portion <NUM> so as to define a generally "C" shaped structure when the vertical portions <NUM> of the first and second clips <NUM>, <NUM> overlap. However, in other embodiments, the connecting devices <NUM>, <NUM> may have any other suitable configuration.

It should be appreciated by those of ordinary skill in the art that the specific views shown in the figures simply illustrate one implementation of the method <NUM> described herein. It should also be appreciated that, although the shear web insert <NUM> is described herein as a single component, the insert <NUM> may be formed from multiple shear web segments coupled to one another within the rotor blade assembly <NUM>. Specifically, embodiments including a multi-piece shear web insert <NUM> may be advantageous when sufficient access to the interior of the rotor blade assembly <NUM> is not available via the access windows <NUM>, <NUM>.

Claim 1:
A method for connecting and repairing a shear web, the method comprising:
dry-fitting a shear web insert (<NUM>) in a rotor blade assembly (<NUM>) to establish a perimeter gap (<NUM>) at an angled perimeter interface (<NUM>) between the shear web insert (<NUM>) and at least one adjacent surface selected from a first shear web (<NUM>), a second shear web (<NUM>), a first side of the rotor blade assembly (<NUM>), and a second side of the rotor blade assembly (<NUM>), and, injecting a bonding paste (<NUM>) into the perimeter gap (<NUM>).