AbstractThe pre‐insertion resistors (PIR) within high‐voltage circuit breakers are critical components and warm up by generating Joule heat when an electric current flows through them. Elevated temperature can lead to temporary closure failure and, in severe cases, the rupture of PIR. To accurately predict the temperature of PIR, this study combines finite element simulation techniques with Support Vector Regression (SVR) optimized by an Improved Whale Optimization Algorithm (IWOA) approach. The IWOA includes Tent mapping, a convergence factor based on the sigmoid function, and the Ornstein–Uhlenbeck variation strategy. The IWOA‐SVR model is compared with the SSA‐SVR and WOA‐SVR. The results reveal that the prediction accuracies of the IWOA‐SVR model were 90.2% and 81.5% (above 100°C) in the ± 3°C temperature deviation range and 96.3% and 93.4% (above 100°C) in the ± 4°C temperature deviation range, surpassing the performance of the comparative models. This research demonstrates that the method proposed can realize the online monitoring of the temperature of the PIR, which can effectively prevent thermal faults PIR and provide a basis for the opening and closing of the circuit breaker within a short period.