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In this paper, taking the minimum metal conductor usage of an air core reactor as optimization goal, the influence of air ducts width and encapsulation number on thermal efficiency and electromagnetic efficiency are analyzed. Combined with the equation constraint conditions for maximum temperature rise conservation, inductance conservation and structure function of reactor considering the change of air ducts width and encapsulation number, the thermal and electromagnetic combined optimization curves are formed, and design results are achieved based on the initial design parameters. Meanwhile, the temperature field simulation model of the reactor is established and the results verify the correctness of the optimization method. According to the design results, the proportionality factor of metal conductor usage is only 0.61 compared with the initial design parameters of the reactor, which shows that the proposed comprehensive optimization method can significantly reduce conductor usage, improving the metal conductor utilization ratio

Thermal and Electromagnetic Combined Optimization Design of Dry Type Air Core Reactor