Umudike Journal of Engineering and Technology

Multi-phase power systems are increasingly gaining traction in industrial and transportation applications due to their high reliability, fault tolerance, and improved power density compared to conventional three-phase systems. While various transformation methods exist, optimizing the specific winding design is critical for maximizing material efficiency and operational performance. This study presents a comprehensive design methodology for the windings of a 3kVA three-phase to five-phase shell-type transformer. Using a special connection scheme across three separate cores, the design equations were derived and subsequently validated through finite element analysis (FEA) using ANSYS Maxwell 2D. Simulation results for a rated phase load of "69.84∠" 〖"31.79" 〗^"0"  demonstrated a high degree of accuracy, with calculated winding currents agreeing with simulated values within a 6% error margin. The system exhibited excellent field performance, maintaining magnetic flux and current densities within specified limits. Furthermore, the transformer achieved a high operational efficiency of 96.07% at the rated load. These results validate the proposed winding design and connection scheme, offering a reliable framework for the future development and optimization of multi-phase transformer systems.