Reactor individual branch loss mutation is one of the important reasons leading to local temperature too high. In order to explore process deviation for dry type hollow shunt reactor loss amplification effect, this paper is establish a loss calculation model of dry-type air-core reactor as the tool, Comparative analysis relationship between the four common types of process deviation and the local branch loss. Calculation results show that the number of turns deviation are the main factor influencing the reactor partial loss, So the reactor production winding process should strengthen the control of the number of turns deviation.

As to current problem of straightness defects and uneven quenching thickness of rail head, heating device with several induction loops are used, and through a three step strategy to realize simultaneously heating to head and bottom of rail. In air jetting phase, spray nozzles are replaced by Al alloy plates(20mm thick) with holes, adjusting to cooling strengthen can be realized by changing cross-section of holes, cooling rate is 2~4°C/sec. After the air jetting phase, there is a waterfog jetting phase, which makes 200°C temperature gap between head and bottom of rail, to ensure quenched rail has good straightness after 48h natural aging.