DesignWithAjay’s Approach to Modular Gearbox Design for Easy Maintenance
At Ajay Industries, we believe that great design doesn’t stop at performance it extends to how easily a product can be serviced, upgraded, and understood.
Our modular gearbox systems are engineered not just for torque and durability, but for intuitive maintenance, component interchangeability, and visual clarity in documentation.
Whether you’re designing for SPMs, industrial shredders, or automation systems, our modular gearboxes simplify the lifecycle of mechanical systems—from assembly to repair.
What Is Modular Gearbox Design?
Modular gearbox design means:
- Interchangeable subassemblies (e.g., gear stages, housings, shafts)
- Standardized interfaces for easy replacement
- Exploded views and BOMs that mirror real-world disassembly
- CAD-driven precision for alignment, tolerance, and fit
This approach reduces downtime, simplifies inventory, and empowers technicians with clear, actionable documentation.
Key Features of DesignWithAjay Gearboxes
1. Split Housing Architecture
- Allows access to internal gears without disturbing shaft alignment
- Reduces service time by 40% compared to welded housings
2. Bolt-On Gear Stages
- Enables quick ratio changes or upgrades
- Ideal for prototyping and field customization
3. Visual BOM Integration
- Every part is linked to a CAD view and part number
- Maintenance teams can identify and order replacements instantly
4. Standardized Shaft Couplings
- Compatible with multiple motor types and torque ratings
- Reduces need for custom machining during integration
5. Drain & Inspection Ports
- Built-in access for lubrication checks and debris removal
- Extends gearbox life and simplifies preventive maintenance
CAD-Driven Maintenance Philosophy
At DesignWithAjay, every gearbox model includes:
- STEP files of all components
- 2D drawings with sectional views for disassembly
- Exploded views with part callouts
- Maintenance notes embedded in the CAD file
- Torque specs and fit tolerances for each joint
This ensures that technicians, designers, and clients all speak the same language—visual, precise, and actionable.
Real-World Example: Spur Gearbox #372
Design: 2-stage reduction with modular casing Use Case: SPM integration for packaging line Maintenance Win: Gear stage swapped in 12 minutes using only 4 bolts and a standard puller Documentation: Delivered with STEP, DXF, and BOM files for full traceability
Why Modular Matters
- Faster Repairs: No need for full teardown
- Inventory Efficiency: Stock fewer parts, serve more models
- Training Simplicity: Visual guides reduce technician error
- Field Flexibility: Adapt gear ratios or motor mounts on-site