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KUKA Robot Controller
Servo/Axis · Advanced
KUKA Robot KRC0048 - REGULATOR LIMIT EXCEEDED <axis number>
This alarm indicates that the following error on the specified axis has exceeded the maximum allowable limit set in the controller's regulator parameters. The axis motor command and actual feedback position have diverged beyond the threshold, meaning the joint is unable to track the commanded trajectory accurately. This typically occurs during motion execution when servo performance degrades or mechanical resistance increases unexpectedly.
KRC0048
KUKA Robot KRC0048 - REGULATOR LIMIT EXCEEDED <axis number>
REGULATOR LIMIT EXCEEDED <axis number>
This alarm indicates that the following error on the specified axis has exceeded the maximum allowable limit set in the controller's regulator parameters. The axis motor command and actual feedback position have diverged beyond the threshold, meaning the joint is unable to track the commanded trajectory accurately. This typically occurs during motion execution when servo performance degrades or mechanical resistance increases unexpectedly.
Common Causes
- Excessive load or payload exceeding axis capacity
- Mechanical friction, binding, or joint wear in the axis drive train
- Servo motor or encoder malfunction or degradation
- Loose mechanical coupling, belt slippage, or gear backlash
- Incorrect regulator tuning or PID gain parameters for the axis
Troubleshooting Steps
- 1Check the axis movement manually by powering off the robot and rotating the joint by hand to identify mechanical resistance or binding points
- 2Verify the actual payload weight matches the programmed tool data in the robot controller configuration
- 3Inspect the encoder feedback signal quality and connector integrity on the affected axis motor
- 4Review and compare current regulator parameters (proportional, integral, derivative gains) against KUKA factory defaults or baseline values
- 5Execute a diagnostic encoder test through the KRC teach pendant diagnostics menu to confirm proper feedback signal resolution and alignment
- 6If mechanical issues are ruled out, adjust regulator parameters incrementally under controlled conditions or contact KUKA service to perform servo motor diagnostics
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