If you’re working with aging or obsolete motion control equipment, you’re probably weighing your options: do you gut everything and start fresh, or try to patch together a fix? The good news is that when it comes to modernizing your motion systems, the answer isn’t always “rip and replace.” In fact, with Rockwell Automation’s Kinetix platform, there’s a smarter, more cost-effective middle ground. It’s called conversion.
At HESCO, we’ve helped customers move away from legacy hardware while keeping their existing machines running. The trick is understanding your options. Whether you’re holding on to older drives and motors or you’re starting to see component failures pop up more frequently, Kinetix offers a path forward that doesn’t involve tearing down everything you’ve built.
Let’s walk through what a Kinetix conversion really looks like, and how you can start modernizing your system without rebuilding it from scratch.
Why Modernization Doesn’t Have to Mean Replacement
If your current motion system is technically still working, it’s easy to put off upgrades. We get it. But as components age out of support and spare parts become harder to source, the risk of unplanned downtime goes up, and so do your repair costs.
That said, full system replacements aren’t always realistic. Machines can be highly customized. Replacing everything can mean rewiring control panels, reprogramming motion profiles, and introducing unnecessary complexity into a system that just needs a performance boost.
This is where conversion comes in. It’s a more strategic approach to modernization that focuses on upgrading what’s needed, reusing what still works, and redesigning only when there’s a real reason to. With Kinetix, that flexibility is built into the ecosystem.
What a Conversion Path Actually Looks Like
When we talk to customers about modernization, we typically walk them through three possible paths: reuse, replace, or redesign.
Reuse is the simplest and most cost-effective option. If your mechanical infrastructure is in good shape, and your machine’s basic motion profile still meets your production needs, you may be able to get away with a controller firmware update and a drive upgrade. This is especially common when the control logic is solid, but the hardware is approaching end-of-life.
Replace involves upgrading key components like drives, motors, or I/O without touching the entire machine. Maybe the network has changed, and your current drives don’t support the protocol you need. Maybe you’re trying to gain better speed control or efficiency. In these cases, targeted replacements can deliver big benefits without triggering a full redesign.
Redesign is the most involved–but sometimes necessary–path. If you’re trying to squeeze more throughput out of a line that’s already maxed out, or if you’ve had repeated failures that point to fundamental design issues, it may be time to revisit the architecture. The upside? You get to take advantage of the latest Kinetix innovations that weren’t available when your machine was first built.
No matter which route you take, the key is to evaluate your current setup first. That’s why we always recommend starting with an Installed Base Evaluation (IBE) to get a clear picture of what you’re working with and what’s at risk.
Your Options Within the Kinetix Family
The Kinetix platform offers a wide range of motors and drives designed to work together, but compatibility varies by model. Some combinations are more flexible than others, so it’s important to check the compatibility matrix or use Motion Analyzer to confirm pairings. As long as you plan accordingly, you can build a system that fits your application and scales with your needs.
For rotary applications, Rockwell’s VPL and MPL servo motors are the go-to choices. The VPL line is optimized for high-performance, high-speed motion and works seamlessly with the Kinetix 5500 and 5700 drives. MPL motors offer more flexibility across torque and speed ranges, which is ideal if you're running varied loads or upgrading an older machine with inconsistent duty cycles.
For linear motion, Kinetix offers a range of actuators, stages, and motors that deliver precise control with minimal mechanical wear. If your application requires high-speed indexing or zero backlash, this is a strong upgrade path. And because there are no belts or gearboxes to maintain, the long-term reliability is hard to beat.
One of the most compelling upgrades we've seen recently is the integration of MagneMover® LITE into motion systems that need scalable, independent-cart conveyance. These systems offer dynamic routing and can run multiple products simultaneously on the same line. It’s a huge step forward for manufacturers who need flexibility without sacrificing speed or control.
The best part? These systems are designed to work together. So even if you start with a simple drive upgrade today, you’re building a foundation you can grow into down the line.
How to Ensure a Smooth Kinetix Conversion
If you’re thinking about starting a Kinetix conversion, here are a few lessons we’ve learned from working with facilities across New England:
Begin by taking a full inventory of your current hardware, including controllers, drives, motors, and communication networks. You’ll need to know what’s active, what’s obsolete, and what’s approaching end-of-life. If you don’t already have this documented, an Installed Base Evaluation is worth the investment. It gives you a snapshot of your automation infrastructure, complete with lifecycle statuses and upgrade recommendations.
Next, focus on compatibility. Just because a drive is “new” doesn’t mean it will talk to your existing controller. Rockwell offers tools and code libraries that can accelerate the design process, but integration still requires careful planning. We’ve seen customers run into issues when trying to pair older rotary motors with newer drives without confirming feedback device compatibility.
Don’t overlook the value of Rockwell’s Motion Analyzer software, either. It can model your motion profile and recommend optimized drive-motor-power supply combinations based on load, speed, torque, and application type.
If you’re unsure which drive family best suits your motion needs, or if you want to avoid over- or undersizing your components, Motion Analyzer can take the guesswork out of the equation. It even flags when your application might require regenerative resistors, oversized bus capacitors, or dual-axis drives for compact panel designs.
Finally, make sure your team (or your system integrator) has experience with the Kinetix platform. It’s powerful, but every environment is different. A partner who understands both the hardware and the application can help you avoid common pitfalls and get your system up and running faster.
Final Thoughts
Motion control modernization doesn’t have to mean ripping everything out and starting over. With Kinetix, you can reuse what still works, replace what’s holding you back, and redesign only when the payoff makes sense.
If you’re dealing with aging drives or trying to decide whether your next upgrade should be a retrofit or a full redesign, we’d be happy to help you think it through. A conversation now can save you downtime later, and maybe even extend the life of your machine by another decade.
Need help getting started? Let’s take a look at what’s on your floor and map out a path that fits your goals, your budget, and your production schedule.
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