What causes KUKA Robot alarm KRC0278?

Excessive payload or payload not properly calibrated in the robot's mass and inertia parameters. Tool collision or robot striking an obstacle during motion, causing sudden load increase. Incorrect acceleration/deceleration ramps or velocity profiles in the motion program. Worn or damaged gearbox components causing increased internal friction and torque requirements. Incorrect gravity compensation settings or zero-position calibration for the affected axis.

How do I fix KUKA Robot alarm KRC0278?

1. Verify the payload mass, center of gravity, and inertia values match the actual tool/workpiece being used via the Payload tool in WorkVisual 2. Check the motion program for excessive acceleration values and reduce them to reasonable limits (typically 10-30% of maximum) 3. Inspect the robot for collisions or mechanical obstructions and clear any obstacles in the work envelope 4. Test the axis movement without payload to determine if the alarm persists, indicating potential internal gearbox wear 5. Review and adjust the gravity compensation parameters in the axis-specific configuration if the alarm occurs during static positioning 6. If persistent, perform axis homing/zeroing procedure and contact KUKA service to inspect gearbox condition and motor encoder calibration

KUKA Robot codes

axismd.ai

KUKA Robot Controller

Servo/Axis · Basic

Alarm KRC0278

KUKA Robot KRC0278 - GEAR TORQUE EXCEEDED AXIS <axis>

This alarm indicates that the calculated torque transmitted through the gearbox of the specified axis has exceeded the maximum allowable gear torque limit defined in the robot's configuration parameters. This typically occurs during high-speed acceleration, deceleration, or when the robot attempts to move against excessive external resistance. The alarm is a protective mechanism to prevent mechanical damage to the gearbox assembly.

KUKA RobotServo/AxisBasic

KRC0278

KUKA Robot KRC0278 - GEAR TORQUE EXCEEDED AXIS <axis>

GEAR TORQUE EXCEEDED AXIS <axis>

Common Causes

Excessive payload or payload not properly calibrated in the robot's mass and inertia parameters
Tool collision or robot striking an obstacle during motion, causing sudden load increase
Incorrect acceleration/deceleration ramps or velocity profiles in the motion program
Worn or damaged gearbox components causing increased internal friction and torque requirements
Incorrect gravity compensation settings or zero-position calibration for the affected axis

Troubleshooting Steps

1Verify the payload mass, center of gravity, and inertia values match the actual tool/workpiece being used via the Payload tool in WorkVisual
2Check the motion program for excessive acceleration values and reduce them to reasonable limits (typically 10-30% of maximum)
3Inspect the robot for collisions or mechanical obstructions and clear any obstacles in the work envelope
4Test the axis movement without payload to determine if the alarm persists, indicating potential internal gearbox wear
5Review and adjust the gravity compensation parameters in the axis-specific configuration if the alarm occurs during static positioning
6If persistent, perform axis homing/zeroing procedure and contact KUKA service to inspect gearbox condition and motor encoder calibration

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