As a key equipment in the power system, the noise problem of dry-type iron core reactor directly affects the stability of equipment operation and the user’s environmental experience. Based on the multi-physical field coupling theory, this study analyzes the vibration noise formation mechanism and optimization control method of Fe-based soft magnetic composite core reactor by combining COMSOL simulation and experimental test. The contributions of Maxwell force and magnetostrictive effect to the vibration of the core are quantified by coupled electromagnetic-mechanical-acoustic field modeling. The results show that the maximum vibration displacement induced by Maxwell force is 3.81×10-5 m, which is much higher than that of magnetostrictive force of 3.56×10-8 m. Aiming at the insensitivity of air-gap structural parameter, the topology optimization algorithm of electromagneticmechanical-acoustic field coupling is proposed, which reduces the vibration displacement of the Fe-based soft magnetic reactor by 90.19% from 9.41×10-7 m to 9.23×10-8 m. After the optimization, the vibration noise formation and control method of the Fe-based soft magnetic reactor are optimized. The optimized Fe-based soft magnetic reactor has a high voltage noise of 45.71 dB(A) and a sound power value of 58.93 dB(A), which are 31.9% and 28.7% lower than that of the conventional silicon steel reactor, respectively.
