As automakers accelerate the shift toward hybrid and electric vehicles, 48V mild hybrid systems have become a cost-effective solution to meet stricter emissions and fuel efficiency standards. Among the critical components enabling this transition is the ISG motor—the Integrated Starter Generator. This powerful hybrid technology plays a vital role in optimizing engine performance, reducing CO₂emissions, and enhancing driving comfort.
In this article, we highlight eight essential insights about ISG motor assembly, from functional principles to cutting-edge automation solutions.
1. What is an ISG Motor?
The ISG motor (Integrated Starter Generator), also referred to as a P1 motor, is a core component of modern 48V hybrid systems. Unlike BSG (Belt Starter Generator) motors, ISG motors are directly mounted on the crankshaft—typically located between the internal combustion engine (ICE) and the transmission.
This design allows the ISG motor to perform dual roles:
Starting and restarting the engine (start-stop functionality)
Providing electric torque assistance during driving
2. How ISG Differs from BSG (Belt Starter Generator)
While both ISG and BSG motors are used in 48V mild hybrid applications, their mechanical configurations and performance levels differ significantly:
|
Feature
|
BSG Motor (P0)
|
ISG Motor (P1)
|
|
Position
|
Belt-driven at engine front
|
Directly mounted on crankshaft
|
|
Drive Type
|
Indirect via belt
|
Direct-drive
|
|
Efficiency
|
Moderate
|
High
|
|
Regenerative Braking
|
Limited
|
Full-featured
|
|
Torque Assist
|
Low
|
Moderate to high
|
Thanks to its direct connection, the ISG motor delivers higher energy efficiency, faster response time, and better integration into hybrid propulsion modes.
3. Core Functions of an ISG Motor in a 48V System
The ISG motor performs several vital roles:
Engine start and restart: smooth and silent operation
Torque assistance: provides extra power during acceleration
Regenerative braking: captures kinetic energy during deceleration
Power generation: charges the 48V battery during driving
Engine-off coasting: improves fuel economy without compromising performance
4. Key Components in ISG Motor Assembly
A typical ISG motor consists of:
Stator: the stationary part that generates a rotating magnetic field
Rotor: integrated with the engine crankshaft
Cooling system: often includes liquid cooling for thermal management
Housing & bearing system: ensures mechanical stability and alignment
Position sensors: for precision control and safety
The compact space between the engine and gearbox demands ultra-precise mechanical integration and high thermal stability.
5. Technical Challenges in ISG Motor Assembly
ISG motor assembly is more complex than traditional automotive motors due to:
Tight mechanical tolerances
Precise rotor-crankshaft integration
High operating temperatures
Vibration and noise control (NVH)
Demand for flawless electrical insulation and stator winding quality
Achieving these requirements manually is time-consuming and prone to errors—automated assembly solutions are essential for mass production.
6. HONEST Automation ISG Motor Assembly Solutions
At HONEST Automation, we offer fully automated ISG motor assembly lines tailored to your specific motor design and production capacity.
Our ISG motor equipment covers:
Stator winding, insertion, forming & lacing
Stator testing: resistance, hipot, surge tests
Rotor balancing and magnetic field calibration
Rotor-to-crankshaft assembly & locking
Automated inspection and traceability system
Our modular system design allows for quick changeovers, high flexibility, and seamless MES/ERP integration for digital factory environments.
7. Advantages of Automated ISG Assembly Lines
Implementing automated equipment brings substantial benefits:
Improved product consistency through repeatable precision
Faster cycle times with less labor input
Higher yield rates and reduced scrap costs
Automated traceability and real-time quality feedback
Future-ready scalability for new motor models or higher volumes
HONEST Automation intelligent systems help manufacturers reduce total cost of ownership and maximize uptime.
8. Why Choose HONEST Automation as Your ISG Assembly Partner?
With over 19 years of experience in automotive motor automation, HONEST Automation is a trusted partner for leading OEMs and Tier 1 suppliers.
Why Global Customers Choose Us:
Customized turnkey solutions for ISG, BSG, PMSM, and BLDC motors
On-site engineering support, installation & training services
Industry-proven designs with successful applications in 48V and high-voltage motors
Global after-sales network ensuring fast response and local support
Request a Customized Proposal Today
As the demand for hybrid solutions grows, investing in reliable, automated ISG motor assembly equipment is critical for staying competitive. HONEST Automation delivers not only machines, but solutions.
Contact our engineering team today to get a personalized proposal and price estimate. We’re here to help you move forward with speed, precision, and confidence.
