Stepper Motor Replace in Pointer Gauges

The world is digital today, and most information is represented in numbers. However, human nature is more “analog” and better represented in an old-fashioned way, using pointer gauges and bar graphs. Pointer gauges can be found in many applications. Automobiles, trains, and even modern aircraft dashboards. It does not look like good old pointer gauges will disappear in the near future.


An efficient way to control a pointer gauge is to use a stepper motor. A stepper motor is an electromechanical device that converts electrical pulses into discrete mechanical movements. The shaft or spindle of a stepper motor rotates in discrete step increments when electrical command pulses are applied to it in the proper sequence. The motor’s rotation has several direct relationships to these applied input pulses. The sequence of the applied pulses is directly related to the direction of motor shafts rotation. The speed of the motor shafts rotation is directly related to the frequency of the input pulses.


Advantages of using stepper motors   

  • The motor has full torque at standstill (if the windings are energized).
  • Precise positioning and repeatability of movement since good stepper motors have an accuracy of 3 – 5% of a step and this error is noncumulative from one step to the next.
  • Excellent responsiveness to starting/stopping/reversing.
  • The motor’s response to digital input pulses provides open-loop control, making the motor simpler and less costly to control.
  • It is possible to achieve very low-speed synchronous rotation with a load that is directly coupled to the shaft.
  • A wide range of rotational speeds can be realized since speed is proportional to the frequency of the input pulses.


A perfect way to control a pointer gauge is to use a small stepper motor specially designed for pointer control. Today, many companies provide stepper motors for gauges which quality varies greatly. SA1077-1 stepper motor is among the first class quality level. And it is an optimal choice for OE replacement, it works just like the original.


SA1077-1 goes exclusively for BMW 7 series / F01 / F02 / F03 / F04 / F07 / F08 / F10 / F11, GT. It is mainly used in dashboard or instrument cluster or some other digital indicator equipment to transfer a digital signal into an accurate analog display. The metal shaft is 8mm long.


Advantages are as follows,

  • High precision in positioning and indication
  • Small & stable hysteresis, minimized position error.
  • Low noise
  • High-temperature capacity
  • High accuracy internal stopper design, internal reset supported
  • Perform smooth movement under micro-stepping control.


SACER Ltd, established in 2007, is dedicated to developing and producing electronic control modules products for automobile aftermarket, covers a total application area of instrument LCD display, ABS/ECU/repair spare parts, DC motor for the throttle body and automobile semiconductors, etc. And an ODM category of turbo actuator, contactless TPS sensor, ECU, window regulator, EPS/EHPS control board and air flow meter, etc. which requires products with highest stable quality and consistent performance to stand out from the fierce market competition. To learn more about SACER and find out what you need, please check it out at our online shop,

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Stepping Motor Heat Treatment Method

Preface: Overheating problem is a general phenomenon for drivers. But what degree of heat is normal , and how to minimize the risk of overheating problems. Continuing to the latter article — “The Overheat Problems For Stepper Motor”

The following is a simple analysis.

The reasons of overheating problems for stepper motor is affected by iron losses, copper losses, even  affected by material, current, frequency, voltage. So the overheating problem is showed by iron losses and copper losses.  Moreover, AC motor frequency of occurrence of fever is relatively high. But as we said according to the latter essay, the reasonable range of the heating of the stepper motor depends on the degree to which the motor is hot, depending on the internal insulation level of the motor.

Internal insulation performance is  at high temperatures (as long as the internal temperature does not exceed 130℃ degrees, the motor will not be damaged, so the surface temperature will be below 90 degrees or stepper motor surface temperature is at 70-80 degrees , which are normal temperature for stepper motor.

The simple skills to test the temperature are as following.

Drivers can touch it within 1-2 seconds if the temperature is under 60℃. But please just touch it quickly if the temperature is between 70-80℃. Drop a few drops of water quickly gasification, then more than 90 degrees.

But the overheating status is also connected to the speed. Stepper motor heating is with the speed of constant change to maintain constant torque output.

Speed to a certain extent, the motor internal back EMF increased. then, The current will gradually decline, the torque will drop automatically.

The solutions of overheating problems for stepper motor.

Solution 1

Increasing the iron losses/copper losses is a good way to avoid the overheating problems. So we can reduce current and resistance. We should choose a small resistance and small current rating of the motor when we decide to purchase it. For two-phase motors, the parallel motor can be used without a parallel motor, but this is often in conflict with the requirements of torque and high speed.

Solution 2

For a motor that has been selected, we should take advantage of the drive’s automatic half-flow control function and offline functions. The former automatically reduces the current when the motor is in static state. The latter one, we can cut off current directly.

Solution 3

Besides, Segment the drive current waveform close to the sine, If the harmonic less, the motor will be less heat. Increasing the iron losses is also related to the voltage.

High-voltage drive motor will bring high-speed characteristics of the upgrade but increasing the overheating problems.

Solution 4

Choosing the appropriate drive-voltage-grade, Taking into account the high band, smoothness and overheating problems, noise and other indicators

Recommend time for reader, now.

Today, editor will introduce a DC Motor for customers. It is a good quality. Because after finishing the test and retest , the item has obtained a lot of good feedback from our customers.


Please follow us if you want to know more information about stepper motor, For example, How to choose a correct stepper motor? What factors effect the overheating of step motor? How could we solve and avoid the overheating problems? and so on . we will update the article later.

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