In order to simultaneously achieve low-speed high torque density and high efficiency in eVTOL direct-drive propulsion systems, an outer-rotor permanent magnet (ORPM) machine is proposed and optimized by semi-analytical multi-objective fast finite element method (FFEM). First, the initial pole-slot configuration and structure of this ORPM machine are discussed. Next, based on the machine loss model, a loss calculation platform is established by using a fast finite element and semi-analytical algorithm. Then, the multi-physics and multi-objective optimization design goals, including torque, torque ripple, and efficiency, are defined for this ORPM machine, with corresponding objective functions and constraints established. Furthermore, optimization calculations are performed using the NSGA-II algorithm, yielding the Pareto front of optimal solutions. Finally, results demonstrate that compared to conventional finite element simulation, the proposed method reduces single-run simulation time by nearly 52%, increases torque density by 27%, and improves overall efficiency by 1%. Compared to traditional finite element methods (FEM), this semi analytical method significantly enhances the computational efficiency for machine loss.
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