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This paper focuses on the development and optimization of a special hybrid electric vehicle arrangement known as a four-quadrant rotary converter. The introduction summarizes the main advantages and disadvantages of existing topologies in radial and axial flux arrangements. Based on previous experience, we developed a novel axial flux arrangement that eliminates the problems and disadvantages associated with existing radial flux solutions. In addition, this paper evaluates and subsequently describes the optimization of permanent magnet parameters in an axial flux rotary converter unit. A number of 3D finite element method optimizations were performed to find the optimal mass distribution of permanent magnets on the frontal area of the outer rotor in the axial flux rotary converter unit. The optimization involved the permanent magnets’ material, shape, and thickness in order to achieve maximal efficiency of the entire unit while leaving its nominal output power and speed unaffected. The results show an increase in the overall theoretical efficiency of the outer rotor unit from 90.2% to 94.4% following the optimization.

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