Product Engineering Center,
       Tipp City, Ohio

The headquarters of our product design, test, and development activities. This modern, 40,000 square foot, three-shift operation is U. L. and CSA approved and recently became one of a limited number of test facilities worldwide that are accredited by NVLAP. Recent expansion and the acquisition of new equipment allow us to test customer products and systems as well as the electric motor, saving development time and streamlining regulatory approvals. At any time, up to 400 motors are on test in our facilities. Sophisticated digital data acquisition tools provide real-time analysis for engineers and technicians.

Computer-aided engineering

Our fully integrated design function uses computer-aided design tools and sophisticated math models to develop a motor design to meet customer electrical, performance, mechanical, and packaging needs. All design information is stored in a single data base for ease of access and to assure efficiency during the development process. We use web-based tools to distribute design information throughout our operations.

Materials analysis

High quality and enhanced efficiency require high-performance materials specially formulated for the application. A. O. Smith conducts extensive raw material analyses in its well-equipped materials and process control laboratories. We evaluate the magnetic properties, grain structure, and chemistry of motor lamination steel. Computerized tests determine the purity of aluminum used for die-cast motor components to assure optimum electrical performance. A. O. Smith's magnet wire test lab is equipped with NEMA MW-1000 test equipment to evaluate performance. Magnet wire (both copper and aluminum) and magnet wire enamels are subjected to a wide range of tests, including scrape resistance, dielectric strength, thermoplastic cut-through, and adhesion. Proprietary windability tests assure magnet wire performs on production winding equipment.

Dynamometer labs

To assure optimum motor performance--particularly the increasing need for motor efficiency, we have 24 state-of-the-art dynamometers ranging in size from 2.5 ounce inch to 5,000 foot pounds. Our dynamometer labs are equipped with proprietary computerized data acquisition and analysis capabilities to within .2 percent accuracy full scale. This lab is capable of testing the entire A. O. Smith motor product line, from 1/100th to 800 horsepower single-phase and polyphase designs.

Torque laboratory

With four custom-designed torque tables, we are able to provide dynamic motor performance curve plotting for precise electrical design profiles as well as U.L. lock rotor testing for all fractional horsepower motors as well as hermetic and integral horsepower products.

Application testing

Hermetic motor lab--A full suite of test equipment to evaluate these precision components used in residential and commercial air conditioning applications as well as air conditioning compressors. Calorimeter tests determine the energy efficiency rating (SEER) and protector development of compressors up to seven ton. This station is capable of testing multiple refrigerants including high pressure. Seven lock rotor test stands to measure motor's performance to this U. L. standard. To measure the motor's durability, we use plug reversal tests that utilize thermal shock, lock rotor amps, and cyclic operation under the most rigorous conditions--up to 250,000 cycles. We developed proprietary equipment to measure end-to-end and side-to-side thrust upon compressor start-up, a critical test to determine the bearing systems' ability to handle the load. Two simulators are used to test varnish/refrigerant compatibility to assure long-term reliability in the field.

Pump products lab--Specialized performance and life tests designed to evaluate 1/8th through five horsepower motors used in water-moving applications as well as pumps and components. Includes a 400 square foot rain room for conducting U. L. testing, water tanks used to conduct cycle testing or to evaluate pump motor designs.

Sound & vibration analysis

With growing consumer interest in quiet operation, we offer an 1,100 square foot semi-anechoic sound chamber. The sound chamber provides isolation below 150 hertz and 25 decibels and is able to test the full range of A. O. Smith motor products. We also provide support in testing customer end products such as air conditioning equipment, water heaters, air compressors, and furnaces.

Performance testing

Environmental tests--Indoor and outdoor tests to evaluate the ability of motors, components, and coatings to withstand the effects of weather and ultra-violet light. Salt fog chambers offer accelerated exposure to corrosive environments using ASTM B117 standards. Environmental chambers expose motors to temperature extremes from -30 degrees (F) to + 300 degrees (F), and moisture levels from 10 percent to 90 percent relative humidity.

Reliability/unit test lab--Typically, anywhere from 200 to 300 motors are on test in this lab. Grueling performance tests include continuous run, repeat start-stop cycling, and extreme load conditions and are used to measure the durability of motors, bearings, capacitors, springs, switches, and other critical components. Frequently, we test motors in customers' end products.Wind tunnel test--We use three wind tunnels (10-500, 100-2,700, and 100-3,500 cfm) to evaluate motor performance in customer-supplied air-moving products such as furnaces, unitary air conditioning compressors, and chillers.

Specialized tests--Depending upon the application or customer requirements, we can conduct unique performance tests, such as lint/dust environments, garage door load simulations, and others.

Electronics lab

With the growing customer interest in electronically controlled motors and enhanced system efficiency, we offer an electronics development lab that is capable of designing and prototyping electronic positioning, sensing, and controlling devices for electric motors. Recent developments include brushless AC and DC controllers, new low-cost variable-speed designs, and an electronic start switch for pump motors. Our engineers not only develop and test the designs but also source materials and components and work with customers on system integration.

Corporate Technology Center

We augment our product engineering operations with the unique capabilities of A. O. Smith's Corporate Technology Center in Milwaukee, Wis. The researchers and engineers of Corporate Technology develop the next generation of product and process concepts, as well as monitor emerging technologies for ideas that may have long-term application with A. O. Smith products. Corporate Technology has special expertise in the areas of electronics, high-performance coatings and related materials, and process technology.