1. Damage Assessment & Engineering
- Visual and ultrasonic inspection of damage.
- Confirm internal spar integrity (shear web, leading/trailing edge).
- Engineering team defines cut line (structural & aerodynamic node).
- Approval per Vensys repair standards and TÜV guidelines.
2. Cutting and Preparation of the Existing Blade
- Mark and cut the blade at the defined 6 m point.
- Taper or step-scarf joint is usually applied (e.g., 8:1 or 12:1 length-to-thickness ratio) to prepare bonding surfaces.
- Remove gelcoat and prepare bonding surfaces via sanding and solvent cleaning.
- Internals (e.g. shear web) are trimmed and prepared for mechanical interface.
3. Fabrication or Delivery of Replacement Tip Section
- Either:
- A pre-manufactured tip is supplied by Vensys or certified fabricator.
- Or, a custom-fabricated composite tip is built using molds and vacuum infusion.
- Tip section includes leading/trailing edge continuity, and may have embedded sensors or lightning protection to connect.
4. Bonding or Mechanical Interface Assembly
- Adhesive bonding of shell surfaces (typically two-part epoxy or polyurethane).
- Spar/Shear web interfaces joined with scarfed laminates or mechanical inserts.
- Use vacuum bagging or clamping to ensure air-tight bond and correct pressure.
- Controlled cure under temperature (may use heaters or tented environment).
Approval
5. Finishing and Reinforcement
- Outer shell laminate patches applied over joint area for strength and airflow smoothing.
- Sanding and application of gelcoat or blade paint for UV/weather protection.
- Reconnection of lightning protection system (conductive mesh and testing).
6. Balancing and Quality Checks
- Static and dynamic mass balancing of the blade.
- NDT inspection (ultrasonic or thermographic) of the joint.
- Documentation of all repairs, materials, cure cycles, and test results.
7. Reinstallation and Testing
- Blade is reinstalled on hub with torque-specific fasteners.
- Turbine undergoes test operation (load monitoring, vibrations).
- All actions logged and certified per Vensys and national wind energy authority regulations (e.g. DIBt).
