• Excessive Load: The motor is being asked to drive a load that exceeds its rated capacity.
• Mechanical Issues: Problems such as bearing failure, rotor imbalance, or misalignment can increase the load on the motor.
• Power Supply Problems: Fluctuations or insufficient power supply can limit the motor's output.
• Drive Configuration Errors: Incorrect settings in the drive, such as current limit or torque control, can contribute to overloading.

Troubleshooting Steps

1. Verify Motor Load:

   • Check the load on the motor: Ensure that it is within the motor's rated capacity.
   • Measure the actual load torque: Use a torque wrench or other appropriate methods to determine the load.
   • Compare the measured load to the motor's rated torque: If the load exceeds the rating, reduce it or replace the motor with a more suitable one.

2. Inspect Mechanical Components:

   • Check for mechanical damage: Look for signs of wear, damage, or misalignment in the motor, coupling, or driven equipment.
   • Test the motor's bearings: Use a stethoscope or vibration analyzer to detect abnormal noises or vibrations.
   • Balance the rotor: If necessary, balance the motor's rotor to prevent excessive vibration and current draw.

3. Verify Power Supply:

   • Measure the input voltage: Ensure that the input voltage to the drive is within the specified range and stable.
   • Check for voltage fluctuations: Use a power quality analyzer to detect any voltage spikes or dips.
   • Improve power quality: If necessary, install a power conditioner or uninterruptible power supply (UPS) to stabilize the power supply.

4. Review Drive Configuration:

   • Check current limit: Ensure that the current limit is set to a value that allows the motor to operate without overloading.
   • Verify torque control: If the drive uses torque control, make sure that the torque setting is appropriate for the load.
   • Review other drive settings: Check for any other configuration errors that might be contributing to the problem.