Pre-assembled Cable Harness for Modular House Electrical Installation
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Solution Overview
Problem
The electrical installation process for modular houses is time-consuming and cost-intensive due to the need for manual routing of cables by a qualified electrician, both during prefabrication and on-site assembly, which increases labor costs and complexity.
Innovation Solution
A pre-assembled cable harness is created outside the building module with bundled cables of specific lengths, allowing for easy attachment and connection to component mounting positions, eliminating the need for individual cable laying and reducing the requirement for a trained electrician, using plug connectors for simple and error-free connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cable routing is performed by a qualified electrician during prefabrication and on-site assembly, then electrical installation reliability is ensured, but installation time and labor costs increase significantly
Solution Approach 1:
Cables are pre-bundled into cable harnesses with predetermined routing paths and connection points before the building module is assembled. The cable harnesses are prepared in advance with cables already positioned and secured along the intended routes, eliminating the need for time-consuming manual routing during installation while maintaining proper electrical installation standards
Solution Approach 2:
The electrical installation is divided into modular cable harness units that can be independently prepared and installed. Each cable harness represents a segmented portion of the overall electrical system, allowing for standardized pre-fabrication and simplified on-site assembly without requiring complete manual installation of individual cables
2Manufacturing precision
If individual cables are manually routed and installed, then precise cable positioning is achieved, but the complexity and cost of electrical installation increase
Solution Approach 1:
Multiple individual cables are merged into a single integrated cable harness assembly. The harness combines several cables with their supporting structures, fasteners, and routing elements into one unified component that maintains precise cable positioning while reducing installation complexity to a single assembly unit
Solution Approach 2:
The cable harness acts as an intermediary component between the building module structure and the electrical components. It provides pre-established cable routing paths and connection points, serving as a mediator that ensures precise cable positioning without requiring complex manual installation procedures
3Productivity
If cables are cut to specific lengths outside the building module and bundled, then installation speed increases, but the precision of cable length matching may decrease
Solution Approach 1:
Cables are cut to precise lengths and bundled into harnesses during the pre-fabrication stage when controlled factory conditions allow for accurate measurement and cutting. This preliminary preparation ensures cable length precision is achieved before assembly, enabling fast on-site installation without compromising dimensional accuracy
Data Source
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AI summary
Building module (1) for a modular house (100) comprising at least one ceiling element (2), at least one floor element (4), at least one wall element (3), wherein at least one, preferably predefined, component mounting position (8, 8a, 8b) for the installation of components (24) is provided in the ceiling element (2) and/or in the floor element (4) and/or in the wall element (3), a main distribution box (20), and at least one pre-assembled cable harness (10, 10', 10"), which comprises at least two, preferably several, cables (26, 27, 28, 30, 31) cut to specific lengths, wherein the cables (26, 27, 28, 30, 31) run from the main distribution box (20) to the component mounting positions (8), and wherein the at least one pre-assembled cable harness (10, 10', 10") contains current-carrying cables (26) comprising the cables (26, 27, 28, 30, 31) of the at least one pre-assembled cable harness (10, 10',10") are at least partially bundled and at least partially arranged parallel to each other.