CCAMTG-2500 A04 — Active Magnetic Bearings & Touchdown System

Volume 06 defines the CCAMTG-2500 A04 Active Magnetic Bearing and Touchdown Bearing subsystem, providing non-contact radial and axial support for the common high-speed rotor train. The system integrates rotor-position sensing, active magnetic bearing control, power amplification, vibration and speed monitoring, cooling, electrical interfaces and mechanically independent touchdown support. During normal operation, the rotor is levitated and maintained around its commanded operating position without continuous mechanical bearing contact. During defined fault conditions, the touchdown-bearing system provides backup mechanical support for controlled rotor coast-down.

Active Magnetic Bearing System Overview

• Non-contact radial rotor support
• Non-contact axial thrust control
• Active rotor centring and position regulation
• Integrated rotor-position sensing
• Integrated rotor-speed and phase sensing
• Vibration and rotor-condition monitoring
• Dedicated AMB controller and power-amplifier architecture
• Mechanically independent touchdown-bearing backup system
• Cooling and thermal-management interfaces
• Integration with machine protection, controls and safety systems

Radial Magnetic Bearing Architecture

• Multiple radial active magnetic bearing stations distributed along the common rotor train
• Radial control in two orthogonal axes at each bearing station
• Continuous non-contact rotor-position correction during operation
• Magnetic actuation coordinated with rotor dynamics and machine loading
• Rotor target surfaces integrated with the shaft and sleeve architecture
• Magnetic core and winding assemblies designed for high-speed machine duty
• Radial stations coordinate compressor, central machine and turbine rotor support

Axial Magnetic Bearing System

• Double-acting active magnetic bearing architecture
• Controlled thrust support in both axial directions
• Continuous axial rotor-position regulation
• Redundant axial position sensing
• Integration with the rotor thrust target and common shaft system
• Axial bearing control coordinated with rotor dynamics and structural loading
• Fault handling integrated with the wider machine-protection system

Touchdown Bearing System

• Independent mechanical backup support at the radial bearing stations
• Used during loss of magnetic levitation
• Supports controlled rotor coast-down during defined fault events
• Not used as the normal continuous running bearing system
• Designed around high-speed transient and thermal fault conditions
• Integrated with startup permissives and condition monitoring
• Coordinated with rotor dynamics, lifecycle and supplier-qualified bearing data

Rotor Position & Speed Sensing

• Non-contact radial position sensing at each radial magnetic-bearing station
• Orthogonal rotor-position measurement for two-axis radial control
• Redundant axial thrust-position measurement
• Rotor phase and shaft-reference sensing
• Redundant rotor-speed monitoring
• AMB-integrated vibration and position channels
• Sensor data integrated with control, protection and diagnostic systems

AMB Controller & Power Amplification

• Dedicated active magnetic bearing controller
• Closed-loop rotor-position control
• Dedicated power amplification for radial bearing stations
• Dedicated power amplification for axial bearing control
• Integration with regulated machine control-power architecture
• Controller stability coordinated with electromagnetic and rotordynamic analysis
• Fault management integrated with PLC, SIS and machine-protection logic

Electrical, Cabling & EMC Integration

• Separate power and sensor signal routing
• Shielded industrial sensor and control cabling
• Machine and enclosure bonding
• Controlled earthing architecture
• Electromagnetic compatibility coordination
• Integration with the wider electrical and control-power system
• Consistent I/O integration with controls, alarms and trip logic

Cooling & Thermal Management

• AMB coils and power electronics treated as defined machine heat sources
• Cooling duty integrated with the CCAMTG-2500 A04 thermal system
• Closed-loop cooling interfaces for magnetic-bearing and amplifier assemblies
• Cooling availability included in startup permissive logic
• Thermal performance coordinated with actual electrical and magnetic losses
• Cooling failure handled through the machine protection architecture

Startup & Operating Permissives

• Cooling availability verified before high-speed rotor operation
• AMB controller health verified before rotor acceleration
• Rotor levitation established before high-speed rotation
• Rotor centred before machine loading
• Touchdown-bearing monitoring verified before startup
• Magnetic-bearing support established before compressor or turbine operation
• Operating permissives integrated with the common machine control sequence

Fault & Coast-Down Functions

• AMB instability initiates coordinated machine protection
• High-pressure energy sources are isolated where required
• Touchdown bearings support controlled rotor coast-down after levitation loss
• High vibration initiates controlled machine shutdown
• Overspeed conditions coordinate turbine isolation and rotor deceleration
• Electrical faults preserve safe rotor control where practicable
• Emergency-stop and fire conditions coordinate energy isolation and safe coast-down

Mechanical Support & Alignment

• All magnetic-bearing and touchdown-bearing stations reference the common rotor axis
• Bearing housings maintain alignment with the machine rotor datum
• Rotor support geometry coordinated with compressor, PMSM/PMG and turbine modules
• Housing and support structures integrated with the structural skid
• Alignment requirements coordinated with rotor dynamics and structural analysis
• Critical mechanical interfaces controlled through released engineering drawings

Materials & Component Architecture

• Magnetic-core assemblies for active bearing actuation
• High-temperature winding systems
• Qualified rotor target sleeves and thrust-target interfaces
• Supplier-qualified touchdown-bearing assemblies
• Structural housings and supports
• Non-contact rotor-position sensor assemblies
• High-strength critical fastening systems
• Protective guards, covers and service panels

Manufacturing & Quality Engineering

• Controlled magnetic-core manufacturing and assembly
• Controlled winding manufacture and electrical verification
• Material certification for critical rotating interfaces
• Machining and inspection of bearing housings and rotor interfaces
• Balance and traceability requirements for rotating components
• Inspection of alignment-critical bores and faces
• Controlled fastening, preload and locking requirements for critical joints
• Supplier and engineering data retained as part of the subsystem quality record

Verification & Acceptance

• Rotor-position sensing verification
• Radial magnetic-bearing functional verification
• Axial magnetic-bearing functional verification
• Static rotor levitation testing
• Closed-loop stability verification
• Rotor unbalance-response verification
• Touchdown-bearing coast-down verification
• Overspeed-protection interface verification
• Cooling-system verification
• Fault-response and safe-shutdown verification

Safety & Protection Architecture

• Independent touchdown support for defined loss-of-levitation events
• Redundant rotor-position and speed monitoring
• Fault management coordinated with machine safety systems
• High-pressure energy isolation during applicable AMB faults
• Controlled rotor coast-down following protection trips
• Guarding of rotating and high-energy machine components
• Protection logic coordinated with PLC, SIS and emergency-stop functions

Interface Summary

• Three-stage compressor rotor system
• Three-stage turbine rotor system
• PMSM/PMG common rotor architecture
• Rotor-dynamics and torsional-analysis system
• Shaft and rotor structural-analysis system
• Thermal and cooling system
• Electrical control-power system
• Controls, PLC, SIS and alarm architecture
• Structural skid and support system
• Fasteners, joints and critical mechanical interfaces
• QA, inspection and NDE system
• Assembly, alignment and commissioning system

Subsystem Documentation

• Active Magnetic Bearing and Touchdown Bearing design specification
• AMB system general arrangement documentation
• Radial magnetic-bearing station assembly documentation
• Axial magnetic-bearing assembly documentation
• Touchdown-bearing assembly documentation
• Rotor-position sensor mounting documentation
• AMB/TDB bill of materials
• Magnetic-bearing load-allocation analysis
• Touchdown-bearing thermal and fault-capacity analysis