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This paper presents the design method of a permanent-magnet (PM) actuator and an intelligent control module for the associated PM contactor. The original design parameters of the PM actuator are obtained using magnetic circuit method. The optimization model for the PM actuator is solved by genetic algorithm and simulated annealing algorithm. A monostable cylindrical 140-A PM contactor is designed, and the corresponding intelligent control module of the actuator is developed. A dedicated control technique based on voltage feedback is proposed to realize the intelligent dynamic adjustment of the making process for the PM contactor. The electromagnetic force calculation model, the dynamic making model of the iron core and contact, the buffering model for the iron core, and the contact bounce model are all built using MATLAB. Experimental results are reported to showcase the correctness of the simulation method and the effectiveness of the feedback control technique to decrease the closing velocities of both the movable contact and the moving iron core that, in turn, will reduce the first and the second contact bounces significantly to lengthen the life span of the device.

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