AISIN Group Products Adopted on the SUV-Style BEV "bZ4X," the First Model of Toyota’s bZ Series

Apr. 15, 2022

News Release


     Products developed by AISIN Corporation (Headquarters: Kariya City, Aichi Prefecture; President: Moritaka Yoshida) and AISIN Group companies have been adopted on the bZ4X, which will be released on May 12.

     The Toyota bZ4X is the first SUV-style BEV of the company’s bZ series. With this bZ4X as a starting point, Toyota Motor Corporation will roll out a full lineup of BEVs. Meeting the requirements specific to BEVs, including driving range and safety, bZ4X is a new vehicle that pursues attractive driving and the sharing of an enjoyable time and space among all occupants.

     AISIN will provide a full lineup of options by utilizing our products, technologies and know-how accumulated so far in a wide range of fields. We will also propose functions and performance that match the characteristics of each vehicle. By doing so, we will meet the expectations of all customers, thereby realizing our group philosophy: Inspiring “movement,” creating tomorrow.

Newly adopted products
■eAxle *For this product, a news release is issued separately in collaboration with BluE Nexus and DENSO.
     The eAxle is an electric drive module that integrates a motor, an inverter, and a transaxle. BluE, AISIN, and DENSO have jointly developed three new models: a 150kW specification (front) for FWD vehicles and 80kW specifications (front and rear) for 4WD vehicles.

     The unit assembly line (Anjo 1st Plant) for this product is a mixed-flow production line that can flexibly produce the three models: the 150kW front unit and the 80kW front and rear units.

     We have newly introduced cellular manufacturing that can produce multiple different models by combining a fully automatic common fixed platform and fluctuation response areas. (Refer to the conceptual drawing.) This cellular manufacturing system enables the production of not only the three models developed this time but also various other types of units in the future by switching the fluctuation response areas.

     Furthermore, the newly introduced assembly machines are characterized by automatic changing of the tool attached to the robot arm. In addition to mixed-flow production, this allows one robot to handle multiple processes, making the production line compact and cost-effective.

     Besides the above, the production line incorporates multiple new production technologies of our own, including an automated transfer system and the visualization of energy using IoT. Geared toward carbon neutrality, the assembly line has achieved a 30% reduction in CO2 emissions (compared to the conventional line). Furthermore, this innovative production line provides solutions to automation, diversity, and various other challenges.

■Rocker EA Material <AISIN>
     This product is a member that is attached to the sides (left and right) of the underfloor battery case to protect the batteries in the event of a collision (side collision). In BEVs, batteries are installed in the entire underfloor area. Therefore, it is necessary to have a structure that protects not only the occupants but also the underfloor batteries in the event of a side collision.
     Through CAE analysis and actual testing, this product has been developed to have a ladder cross-sectional structure that can absorb energy optimally. In the event of a side collision, the product itself is deformed optimally to absorb energy, reducing the impact transmitted to the batteries. Using aluminum, the product helps reduce vehicle weight.

     This product is a member that holds the Electricity Supply Unit (ESU) newly introduced by Toyota Motor Corporation. The ESU is a unit that integrates the charging and power distribution functions, serving as an important component that plays a central role in the BEV electrical system.
     The adoption of an integral aluminum die-cast structure instead of the conventional steel frame structure allows this product to ensure sufficient rigidity and significantly reduced weight. In addition, low-pressure casting technology allows downsized equipment, helping reduce costs.

■Car Navigation System <AISIN>
     This is a connected navigation system that uses map information on the cloud to obtain traffic information and parking space availability information in a timely manner. In addition to the normal navigation function, BEV specialized functions are available, including a travel support function that proposes a charging station along the route as a stopping point in advance if the navigation system determines that it is impossible to reach the destination based on the battery power remaining at the time of destination setting, a circular driving-range display, and charging station search that suggests charging stations in the vicinity when the battery is low.