In an example, a method is described. The method comprises forming a single hole into a bond gap repair area. The method also comprises evacuating, via an adhesive injection apparatus attached to the single hole, the bond gap repair area and an injection channel of the adhesive injection apparatus. The method also comprises forcing adhesive through the evacuated injection channel and into the evacuated bond gap repair area.

An example method of joining a first structure and a second structure is described that includes placing an adhesive within a bond cavity for bonding a first structure to a second structure, securing a vacuum bag to the first structure and the second structure so as to surround a portion of the first structure and the second structure, evacuating the bond cavity via a vacuum port to deaerate the adhesive within the bond cavity, after deaerating the adhesive, moving the first structure and the second structure relative to one another such that deaerated adhesive is disposed between the first structure and the second structure, and curing, via one or more heaters, the deaerated adhesive disposed between the first structure and the second structure to bond the first structure to the second structure.

Systems and methods are provided for consolidating thermoplastic parts. One embodiment is a method of automatically forming a thermoplastic composite structure. The method includes heating a thermoplastic preform to a forming temperature, forming the thermoplastic preform into a thermoplastic part having a desired shape, aligning multiple thermoplastic parts together, and consolidating the multiple thermoplastic parts together while controlling crystallization to form a complex thermoplastic part.

The disclosure relates to an assembly comprising a component rotatable about a rotary axis for an actuating drive comprising a sensor element attached to the rotatable component. The rotatable component has a support surface from which a fixing element protrudes in parallel to the rotary axis. The sensor element includes an opening. The sensor element is arranged on the support surface in such a manner that the fixing element penetrates the opening. A surface of the sensor element adjacent to the opening has a structure. A top portion of the fixing element is in interlocking engagement with the structure so that the attached sensor element is connected to the component in a torque-resistant manner.

An end effector, for adhesively attaching a first part to a second part, comprises a support and a first nozzle, coupled to the support and movable relative to the support, and a second nozzle, coupled to the support and movable relative to the support. The first nozzle comprises a first-nozzle body, comprising a first-nozzle-body outlet port and a first-nozzle separator plate, extending from the first-nozzle body. The second nozzle comprises a second-nozzle body, comprising a second-nozzle-body inlet port and a second-nozzle separator plate, extending from the second-nozzle body. The end effector further comprises a roller, coupled to the support, rotatable relative to the support about a roller axis, and located between the first nozzle and the second nozzle.

A system and method for welding thermoplastic components by positioning and moving a heated plate between the components to melt their respective faying surfaces, and as the plate moves, pressing the components together so that the melted faying surfaces bond together as they cool and re-solidify, thereby creating a composite structure. The plate has a heated portion which is positioned between and heated to melt a portion of the first and second faying surfaces. A manipulator mechanism moves the plate along an interface from between the portion to between a series of subsequent portions of the first and second faying surfaces, thereby welding the thermoplastic components along the entire interface to create the composite structure. An injection device may also move behind the plate and reciprocally inject a polymer between the first and second faying surfaces to provide toughness and crack arresting properties.

The method for producing an assembly is a method for producing an assembly equipped with a member to be reinforced (20), a reinforcing member body (41), and a filler (42), wherein the reinforcing member body (41) has a pair of flanges (44) arranged spaced on the surface (20B) of the member to be reinforced (20), a web (45), and a connection portion (46) which connects the flanges (44) and the web (45) and forms a filler space (V) with the surface (20B). The method for producing an assembly includes a step for inserting a filler (42) into the filler space (V), a step for attaching a crack control member (43) to cover the end of the filler (42), a step for joining the flanges (44) and the member to be reinforced (20), and a step for curing at least the member to be reinforced (20).

The present invention relates to a system and method for attaching a wind turbine blade component to a surface of a wind turbine blade shell part at a component attachment position. The system comprises a blade shell part support for supporting the blade shell part, a jig comprising a jig base and a component platform for receiving and holding the wind turbine blade component in a first position above at least a part of the blade shell part, the component platform being arranged on the jig base and being at least vertically displaceable relative to the jig base by displacement means to allow the wind turbine blade component to be lowered from the first position to the component attachment position.

A wind turbine blade and associated method of manufacture is described. The blade comprises an outer shell formed of first and second half shells joined together. A shear web is arranged inside the outer shell. The shear web has a web panel disposed between first and second longitudinally-extending mounting flanges. The shear web is bonded to inner surfaces of the respective half shells via a first adhesive bond line between the first mounting flange and the inner surface of the first half shell and a second adhesive bond line between the second mounting flange and the inner surface of the second half shell. One or more bond spacers are provided in the second bond line, and optionally in the first bond line. The bond spacers are compressed between a shear web mounting flange and an inner surface of a half shell and are plastically deformed. The method of making the shear web involves compressing and the one or bond spacers in the bond line(s) such that they undergo plastic deformation. This results in high quality bond lines.

A sonotrode includes multiple layers of a material melted to one another to form a structure. The structure provides a base that has an attachment feature that is configured to operatively secure to an ultrasonic converter. The structure includes a shaft that extends from the base to a terminal end that provides a working surface that is configured to selectively engage a workpiece.