The short story
Volvo Construction Equipment (VCE) required a replacement for their Powertronic Transmission Electronic Control Unit (TECU) due to end-of-life constraints. Facing tight timelines, they partnered with RT-Labs to develop a new unit, designed to handle demanding environments with high reliability.
By using RT-Labs’ RT-Kernel as operating system, advanced diagnostic services, and the Application Component Framework (ACF), the Tecu platform was successfully delivered, paving the way for production in Volvo’s Tuve facility starting in 2025.
The Challenge
VCE’s Powertronic TECU, critical for their heavy-duty construction-vehicles, was reaching the end of its lifecycle. This component was essential for gear shifting in low-volume, rugged-use trucks, such as those equipped with Powertronic systems (as opposed to I-Shift systems used in standard trucks). Volvo needed a replacement unit quickly to meet production demands.
The project presented several challenges:
Time Pressure
Two years from request to planned production start.
Complexity
TECU needed to operate in harsh conditions while maintaining precise transmission control.
Integration Needs
The system required seamless integration with Volvo’s existing production flow and compatibility with the previous generation’s application software.
Functional Requirements
Integration of DEM (Diagnostic Event Manager), UDS (Unified Diagnostic Services), and J1939 communication protocols was essential for the new TECU.
The Solution
RT-Labs delivered a robust solution by combining expertise in real-time systems with cutting-edge tools and frameworks. RT-Labs collaborated with Br. VOSS for hardware development, while VCE reused application code from the previous generation, ensuring continuity and faster development cycles.
RT-Kernel for NXP S32K3
Provided deterministic, real-time performance on the selected hardware platform.
Application Component Framework (ACF)
Simplified the foundation and architecture by specifying tasks, signals, functions, and deadlines. ACF also allowed for visualizing the system as a UML-style diagram, providing clarity on task interactions and enabling better insights into the application architecture.
Diagnostic and Communication Protocols
Implemented DEM and UDS to meet automotive standards and added J1939 for vehicle communication.
Boot Sequence Development
Delivered a complete boot chain (PBL and SBL) to ensure system reliability.
Quality verification
Used RT-Robotest with Hardware-in-the-Loop (HIL) setups to validate the system’s performance and functionality.
The Result
The Transmission Electronic Control Unit (Tecu) was successfully developed and is set to enter production in 2025 at Volvo’s Tuve facility. The platform integrates seamlessly into Volvo’s production flow, supporting low-volume manufacturing while maintaining the rugged reliability required for Powertronic systems.
RT-Labs’ innovative use of ACF provided a clear application architecture, reducing development complexity and enabling Volvo to focus on application-specific innovations. The inclusion of advanced diagnostics, communication protocols, and thorough testing ensured the TECU met all functional and operational requirements.
This collaboration demonstrated RT-Labs’ ability to deliver high-complexity, time-sensitive projects, reinforcing their role as a trusted partner in the automotive industry.