An "Overload Fault" in a KUKA robot indicates that the system has detected an excessive load or force that exceeds the robot’s designed capacity. This fault is triggered to protect the robot’s components from damage and ensure safe operation.

Overload fault in a KUKA robot indicates that one or more of its motors are exceeding their rated current capacity.This fault comes if the robot is attempting to lift or manipulate a weight that exceeds its rated payload capacity, it can trigger an overload fault.

Troubleshooting Steps:

1. Check the Load:

   • Verify Load Specifications: Ensure that the load being handled by the robot is within its rated capacity.
   • Balance the Load: Make sure that the load is properly balanced and not causing excessive strain on any part of the robot.

2. Inspect for Mechanical Issues:

   • Examine Joints and Parts: Look for any mechanical jams, blockages, or misalignments in the robot’s joints and moving parts.
   • Check for Friction: Ensure that all moving parts are properly lubricated and operating smoothly.

3. Review Configuration Settings:

   • Check Parameters: Verify the robot’s configuration settings and parameters related to load limits and safety.
   • Adjust as Needed: Correct any misconfigurations to align with the robot’s capabilities and the load being handled.

4. Examine Components:

   • Inspect Motors and Drives: Check for any signs of malfunction or damage in the motors and drive units.
   • Test Operation: Ensure that all components are functioning correctly and within their specified limits.