A Unique Blend of Design,
Engineering and Manufacturing.

Keeping You on the Leading Edge
of Power Technology.

Whether it’s an emergency propulsion control on a nuclear submarine or a VFD motor on an oilrig, we know our customers have highly specialized power requirements. That’s why Ward Leonard encourages close customer involvement in all stages of production. We’ll work with you, one-on-one, to ensure that your exact requirements are met. We use ANSYS® software, to get a design right on the first build. And we have the ability to provide stand-alone systems or flexible components that will seamlessly integrate with another manufacturer’s equipment.

Our research, development, and manufacturing capabilities are second to none. And as both the military and private industry increasingly focus on lean processes, we are doing the same. Cutting lead times. Creating a highly efficient supply chain staffed with experienced managers. Building an ultra-reliable supplier network. And upgrading our manufacturing facilities. We live by continuous improvement and take that spirit into your programs and assignments.

To find the precise combination of services for your current challenge, call us at (860) 283-5801 or contact us here.

  • Electromagnetic design and motor development competence totaling more than 100 years
  • Design, development, manufacture and repair of mechanical rotating equipment
    • up to 600 hp @ 3600 rpm
    • up to 2000 hp @ 1000 rpm
    • 900kW @ 480VAC generation capacity 57Hz to 62Hz
    • 500kW @ 480VAC generation capacity 50Hz to 65 Hz
    • Electrical loading 200kW continuous @0.4pf for gen-sets
    • 180,000 Btu Water Chiller
    • 300,000Btu Water to Air Exchanger
    • 2,500 gallon Buffer Tank for cooling with 300GPM pump capacity
    • Variable Frequency Drives of 5hp, 10hp, 25hp and 600hp
  • Electromagnetic design with Ansys RMXpert and Finite Element Analysis modeling capabilities with Ansoft Maxwell 2D software
  • Motor equivalent circuit modeling and analysis of external circuits
  • Structural Finite Element Analysis modeling expertise using SolidWorks-Cosmos software
  • Computational Fluid Dynamics analysis expertise in motor and controller thermal analysis utilizing CFDesign software

  • Machining
  • Turning up to 8 feet in length and 32 inches in diameter
  • Cylindrical grinding 5 feet in length and 11 1/2 inches in diameter
  • Balancing up to 110 inches in length and up to 5,000 pounds
  • Vertical turret lathe – 54 inches in height and 54 inches diameter
  • Vertical and Horizontal NC machine centers
  • Fabrication
  • Painting - Paint booth 24 ft. X 14 ft. X 9 ft. high
  • Welding to MIL-STD- 248, 278
  • Brazing - Torch & Induction
  • Sheet Metal Fabrication
  • Amada CNC Turret Press
  • Core Plate Fabrication
  • Blanking up to 32 inches in diameter
  • Notching machines
  • Coil Fabrication
  • Hard & Soft Coils
  • Banding, taping and undercutting
  • Motor Varnishing
  • VPI System - 5 ft dia, 7 ft depth - Multiple Resin Capable
  • Standard Varnish Tank - 6 ft dia, 7 ft depth

  • Turret lathe: Turning up to 30.0” dia.
  • Engine lathes: Shafting up to 10.0” ft. long x 32.0” dia.
  • Cylindrical O.D. grinding: 14.0” dia. x 8.0” ft. length.
  • Horizontal and Vertical CNC machining, 4 axis, up to 32.0” dia.
  • Vertical CNC  turning: up to 60.0” dia.

All secondary operations

  • Surface grinding, milling, drilling, keyways, broaching, grit blast, degrease, and paint.
  • 25 to 150 ton press capability, single and progressive dies, with coil feeder.
  • Programmable servo indexing machining of laminations.  
  • 50 ton Hydraulic assembly press, 72.0” length.
  • Heat treat and stress relieve to 1500° F.
  • Sealed insulation procedure per MIL-STD 2037. NAVSEA approved.
  • Overhead crane capability up to 10 tons.
  • CMM inspection capability for all machined parts.

  • Welding procedures qualified to NAVSEA S9074-AR-GIB-010/278
  • WPS: GTA-1 Approved VPAR, E.B. reference no. QE#FS2060
  • WPS: GMA (SP)-1/1/6 Approved VPAR, E.B. reference no. QE#F50615
  • WPS: SMA-F4 Approved VPAR, E.B. reference no. QE#FS0617
  • WPS: GTA-22/22/22 Approved VPAR, E.B. reference no. QE#F50620
  • Welders/Brazers qualified to NAVSEA S9074-AQ-GIB-010/248. Approved Training Program, TW-P1.

  • 1/10th Thru 1500 HP
  • Single or 3 Phase AC up to 440V
  • DC thru 60 HP@ 460V or 10 HP @ 750 V
  • In-house Shock Testing (lightweight up to 500lb)
  • Vibration Testing up to 300lb, 4-50Hz
  • Dynamometer Testing
    • 120oz-in @ 4000rpm
    • 100lb-in @ 4000rpm
    • 3.25hp @ 2000rpm
    • 5hp @ 1800rpm
    • 6hp @ 3600rpm
    • 25hp @ 1800rpm
    • 40hp @ 3600rpm
    • 200hp @ 3600rpm
    • 800hp @ 3600rpm
    • 2000hp@ 1800rpm
  • Submergence Testing
  • IP54 Spray Testing (100 gallons/min, 10 ft. height)
  • Electrical Testing
    • up to 440VAC@ 810 1s on and 9s off @ o.45pf
    • 1000A inductor for 0.2pf to unity

Generators & MG Sets

  • Up to 375KW 60 Hz or 400 Hz NDT
  • Level 1 and Level 11 visual weld inspection per NAVSEA T9074-AS-GIB-010/271.
  • Approved procedure, WL NDT VT-278, and written practice WP-WP271.
  • MT, PT, RT, outsourced through Marion Testing and Inspection.

Miscellaneous Testing

  • Airborne & Structureborne Noise per MIL-STD-740-1, -2
  • Shock Testing per MIL-S-901 (Lightweight)
  • MIL-STD-167 Vibration Testing
  • 4-55 Hz to 300 Lbs
  • Electrical Life
  • 0-500 AMP AC @ 0-480V
  • 0-3000 AMP AC @ 440-484V
  • Mechanical Life Testing
  • Electrical Endurance Testing
  • Thermal Cycle Chamber Dielectric (high potential voltage) Testing
  • Megger (insulation resistance) Testing