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The paper presents a method of profiling the phase currents to minimize the torque ripple of switched reluctance machines (SRM) operating in four quadrant mode over the entire speed range of operation. A single quadrant current profiling presented in  is extended to be applicable in the four quadrant mode of operation. The method is based on machine and controller design through coupled simulation of the finite element based machine model and the dynamic controller model. The coupled simulation considers the magnetic nonlinearities, electrical and magnetic losses, and mutual coupling. The research quantifies the effect of position sensor error and manufacturing build variations on the level of torque ripple minimization. The mitigation processes to account for those issues in mass production are also presented.