Structural Parameter Optimization Design of a New Hybrid Repulsive Force Mechanism Based on Orthogonal Experiments

Background/Introduction: Flexible DC transmission demands higher circuit breaker performance. Traditional electromagnetic repulsive mechanisms face limitations in medium/high voltage applications due to short strokes and low energy density. This study optimizes a new hybrid repulsive mechanism to enhance both mechanical service life and driving performance. Method: A finite element model of a coil-solenoid system was developed. Single-factor and orthogonal experiments analyzed the effects of winding height, thickness, radial turns, and axial layers. Linear regression and multi-objective optimization were used to minimize force/current peaks and maximize displacement. Results: The optimal parameters were: solenoid winding height = 6 mm, thickness = 2.5 mm, radial turns = 6, axial layers = 11. This configuration achieved the best driving characteristics. Discussion: The results demonstrate that increasing radial turns improves displacement, while other parameters significantly reduce repulsive force and current, thus balancing breaking capacity and mechanical longevity. Conclusion: The orthogonal experiment-based approach effectively optimizes solenoid parameters, ensuring long-stroke rapid breaking capacity and extended mechanical service life.