As　a　new　controlled　apparatus,　intelligent　AC　contactor　has　overcome　shortcomings　of　conventional　AC　electromagnetic　contactor　such　as　closure　behavior　affected　by　AC　phase　angle,　noise,　power　consumption.　However,　the　cost　has　increased　and　reliability　has　decreased　since　the　electronic　control　module　used.　Therefore　it＇s　necessary　to　take　optimization　design　to　improve　overall　performance　of　intelligent　AC　contactor.　The　paper　takes　the　AC　contactor　with　let-through　current　of　630A　as　research　object.　The　3D　dynamic　simulation　model　is　established　considering　the　nonlinear　contact,　collision　problem　and　elastic　material　deformation.　With　the　coil　power　supply　under　intelligent　control,　the　ant　colony　algorithm　is　applied　in　optimization　design　of　electromagnetic　system.　During　optimization,　the　objective　function　is　obtained　by　dynamic　model　based　on　the　magnetic　field　method.　The　results　show　that　icon　and　copper　used　in　electromagnetic　system　have　reduced　greatly　on　the　condition　that　the　intelligent　control　module　used.　A　contactor　prototype　with　intelligent　module　is　manufactured,　and　dynamic　characteristics　are　calculated　and　verified　by　the　experiments　as　well.