In many maintenance projects, the real problem is not that you ordered the wrong size, but that your machine is using an old, discontinued linear guide model. When the original part fails and the model is no longer in production, you need a clear replacement strategy – especially if you are searching for linear guide manufacturers who can support long-term service and HIWIN-compatible solutions.

A European customer contacted us with a simple question:

“The linear guide on our machine is damaged and the model is obsolete. Can you offer a replacement?"

The machine had been running for over 10 years. The original linear guide was discontinued, and no identical model was available on the market. In this kind of old machine maintenance or line upgrade scenario, two key questions must be answered:

• Is the existing guide interchangeable or non-interchangeable?
• If it is non-interchangeable, can we still replace only the block or nut, or do we need a full set?

We asked the customer to share:

• Photos of the rail, block and nameplates;
• Mounting hole dimensions on the base;
• Overall rail length and effective stroke.

Based on the brand information and all dimensions, we determined whether the existing system was interchangeable or non-interchangeable.

Interchangeable means standardized dimensions: blocks can be exchanged on any rail of the same size and accuracy class.

• Within the same series, size and accuracy class, blocks are dimensionally interchangeable.
• Blocks and rails are not factory matched as a fixed set.
• For maintenance, you can often replace only the block and keep the rail.

Typical description: Interchangeable: blocks within the same series can be replaced freely on any rail of the same size and accuracy class.

Non-interchangeable means the block and rail are factory matched and should be used together.

• Each block and rail are supplied as a factory-matched set.
• It is not recommended to mix blocks and rails from different sets.
• For maintenance, you usually need to replace the rail and block together.

Typical description: Non-interchangeable: block and rail are factory matched as a set and should not be mixed with other rails.

In real projects, most obsolete linear guide cases can be handled by one of the two paths below.

For the first customer, the original guide turned out to be an interchangeable type. The old model was obsolete, but the brand had released an updated replacement series with fully compatible mounting dimensions and only a slightly different block length.

Our process was simple and structured:

• Compare the old model and the new series: rail width, hole spacing, rail height, block mounting hole pattern, reference surfaces and overall height.
• Confirm that the effective stroke is not reduced.
• Check that there is no interference with surrounding parts.

After confirming all of this, we recommended:

Option A: Replace block only (interchangeable replacement) – keep the original rail on the machine and use a new-generation interchangeable block as the replacement.

The customer benefits were clear:

• Shorter downtime: no need to remove or re-align the rail.
• Lower cost: only the block is replaced, not the full set.
• Lower risk: standardized dimensions and interchangeable design make it close to a plug-and-play solution.

In another project, the machine used a non-interchangeable early-generation guide. The series was fully discontinued, and there was no single block or official interchangeable model available on the market.

This is a typical situation: non-interchangeable + obsolete = full set replacement required.

Our approach was as follows:

• Request photos and nameplates of the existing guide, along with mounting hole spacing, overall length, effective stroke and available space.
• Redesign a new complete guide system: choose a suitable series (for example HG / EG / RG / MGN / MGW), match rail width, hole spacing and block height to the machine, and design adapter plates or new mounting holes if necessary.

The final solution was: Option B: Full set replacement – rail and blocks supplied together. A new rail and matching blocks were delivered as a complete set.

In the quotation and technical note, we clearly explained:

• Stroke might change slightly (for example ±5–10 mm), depending on the available installation space.
• Some mounting holes might need to be re-machined or an adapter plate may be required.
• Rigidity and preload could match or even improve compared with the original system.

The same logic applies to ball screws. When you work with experienced linear guide manufacturers who also produce ball screws, you can often use a similar decision tree:

• If an interchangeable ball nut is available with matching shaft diameter, lead and accuracy, you can replace the nut only and keep the existing screw shaft.
• If the original product is non-interchangeable or fully customized and now discontinued, you usually need a complete replacement set: nut, screw shaft and support units, redesigned as a whole.

In many projects, the first request is simply “Can you ship something quickly?". But when obsolete models, interchangeable vs non-interchangeable types and full-set replacements are involved, you actually need a linear guide manufacturer, not just a trading company.

With our in-house brand TranzBrillix (TRANZBRILLIX), we design and produce TranzBrillix linear guides that:

• Follow the main HIWIN linear guide mounting dimensions in many popular sizes, so they can be used as compatible replacements for HIWIN linear guides in a wide range of applications.
• For interchangeable-type cases, if the original rail on the machine is from HIWIN, we can evaluate a mixed solution such as TranzBrillix block + original HIWIN rail, as long as the dimensions and performance allow.
• For non-interchangeable or fully obsolete HIWIN models, we can supply a complete TranzBrillix replacement set engineered according to the original installation space: rail and blocks as a full kit.

In all technical documents and offers, we make it clear that the parts are TranzBrillix compatible replacements, not original HIWIN products. The value we deliver is:

• Dimension compatibility with existing HIWIN-based designs;
• Equivalent or better performance in terms of load, rigidity and precision;
• Controlled lead time from a manufacturer with its own production lines;
• More competitive cost for long-term maintenance and machine upgrades.

So when customers search on Google for “linear guide manufacturers" and look for a supplier who can replace HIWIN on existing machines, they are not just buying another rail. They are getting a complete engineering solution built around interchangeable / non-interchangeable logic and long-term service.

When you face obsolete models and old machine repairs, do not rush to say that replacement is impossible. Instead, help the customer answer three simple questions:

1. Is the existing product interchangeable or non-interchangeable?
2. Is there any updated or compatible series available on the market?
3. If no direct interchangeable option exists, can we design a full set replacement to bring the machine back to stable operation?

Once this logic is clear – interchangeable means “block or nut only", non-interchangeable usually means “full set replacement" – maintenance decisions become much easier. Customers see structured engineering reasoning instead of feeling that someone simply wants to sell more parts. That is exactly where manufacturer-level suppliers, such as TranzBrillix, create long-term value in the linear motion market.