Wind turbine rotor blade components and machine for making same

1. A method for making, storing, dispensing, tapering, cutting and stacking one or more preform layers of material to form a structural element for a wind turbine blade comprising the steps of:

(a) providing a preform layer of material of certain length dimensions and certain width dimensions, the preform layer of material including multiple elongate strength rods arranged longitudinally and parallel relative to one another and to the length dimension of the preform layer of material in a single layer, a fixed distance apart, each strength rod being disposed adjacent to and spaced from at least one adjacent strength rod;

the preform layer including at least one carrier layer to which the multiple strength rods are joined and being of a permeable material suitable to facilitate the flow of liquids through the carrier layer;

(b) dispensing lengths of the preform layer of material;

(c) partially grinding through portions across the width of the preform layer of material at predetermined lengths along the length of the preform layer of material to form a V-shape across the width of the preform layer of material; and

(d) cutting the grinded portions of material at the vertex of the V-shape to produce cut preform layers of predetermined lengths;

(e) stacking each length of cut preform layer with one or more other preform layers;

(f) causing liquid bonding resin to flow between adjacent strength rods and through the carrier layer to which the strength rods are joined and to adjacent stacked preform layers; and

(g) solidifying the liquid bonding resin to fix the stacked preform layers to form a structural element for a wind turbine blade.

2. The method of claim 1 , wherein the step (e) further includes the step of stacking the layers of preform materials in at least one of a column pattern or a brick pattern.

3. The method of claim 1 , wherein a programmable controller is provided and controls at least the operations of one or more of steps (b), (c) and (d).

4. The method of claim 3 , wherein the programmable controller controls the length and depth of the V-shape grinding across the width of the preform layer of material.

5. The method of claim 1 , wherein a programmable controller controls the operation of cutting the grinded portions of the material at the vertex of the V-shape.

6. The method of claim 1 , further including the step of providing a programmable controller, and wherein the programmable controller includes a menu for saving different lengths of the preform layers of material in a storage system associated with the programmable controller.

7. The method of claim 6 , wherein the programmable controller includes a menu for saving lengths of leading and trailing tapers of the preform layers of material in a storage system associated with the controller.

8. The method of claim 1 , further comprising the step of storing coiled lengths of the preform layer of material provided from step (a).

9. The method of claim 8 , wherein the step (b) of dispensing lengths of the preform layer of material is provided from the stored coiled lengths of material.

10. The method of claim 1 , wherein the step of grinding is performed by grinding with one of an abrasive roller, an abrasive belt or a traversing abrasive wheel.

11. The method of claim 1 , further comprising providing an encoder operatively associated with a nip roller, the encoder being in operational communication with a programmable controller which determines positional information of a preform layer of material in contact with the at least one nip roller or encoder wheel.

12. The method of claim 11 , further comprising the step of the programmable controller using positional information from the encoder to determine the cut length of the preform layer of material.