The short story
Volvo faced an ambitious challenge: creating a cab-less, self-driving truck named VERA to showcase at a prestigious trade show in Berlin. The trade show was merely the first step. Behind the scenes, Volvo had its sights set on a larger, groundbreaking goal – transforming the future of logistics. VERA was designed to operate autonomously, transporting goods between Gothenburg’s port and Volvo’s factory in Torslanda. This pilot project not only pushed the boundaries of innovation but also marked a significant milestone in Volvo’s vision for smarter, greener, and more efficient transport solutions. VERA wasn’t just a concept; it was the first glimpse of a logistics revolution.
To meet the initial goal, they needed two new ECU’s – a Power Distribution Unit (PDU) and a Vehicle Control Module (VCM) to replace traditional cab-based systems. With a tight deadline and complex requirements, Volvo partnered with RT-Labs to deliver fully functional prototypes.
The Challenge
For the VERA project, Volvo envisioned a cutting-edge, autonomous transport solution without a traditional driver’s cab. This vision demanded the complete removal of all cab-based control units, necessitating the development of two new components: the Power Distribution Unit (PDU) and the Vehicle Control Module (VCM). The PDU would replace the traditional relay box, manage power distribution for up to 20 other units. Meanwhile, the VCM unit would act as the truck’s central brain, coordinating communication between 10 CAN based networks, LIN, 1000base -T & -T1 ethernet while simultaneously calculating optimal routes from point A to point B based on input from a higher-level navigation system.
The timeline was exceptionally tight. Volvo’s team needed the prototypes ready for a major trade show in week 36 and RT-Labs received the assignments just before the Christmas holidays. Adding to the complexity, both the PDU and VCM had to be designed and developed from scratch. Volvo’s reliance on Simulink models required seamless integration with their existing workflows. The stakes were high, and the pressure to deliver was immense.
The Solution
RT-Labs took on the challenge with a tailored approach:
RT-Labs provided the necessary components and services required for seamless integration into AB Volvo’s production and aftermarket infrastructure. This included a primary and secondary bootloader, transport protocols, a diagnostic core, and the real-time operating system RT-Kernel, ensuring robust and deterministic performance. For both the STM32-based PDU and the Xilinx Zynq Ultrascale-based VCM, RT-Labs also supplied a complete toolchain for development and integration. In the case of the PDU, RT-Labs took full ownership by also developing the entire application, delivering a complete, production-ready product solution.
STIG (Simulink Target Interface Generator) is a module based system for automatic code generation using simulink generated code as input. This proprietary tool allowed Volvo to quickly get their Simulink developed control loops up and running, speeding up the application development.
View product: STIG (Simulink Target Interface Generator)
By deploying RT-Robotest for automated HIL (Hardware-in-the-Loop) testing, RT-Labs could validate the functionality and integration of both the PDU and VCM in real-time.
Partnering with Br. VOSS for hardware and Volvo’s Special Vehicles division at GTT, the PDU and VCM were designed to meet the unique needs of autonomous and electric vehicles.
The PDU included CAN communication and advanced power I/O features & diagnostics, addressing the specific demands of the VERA project. The VCM, with its high complexity, served as a communications hub and central control system, enabling precise vehicle operation and route calculation. Volvo’s existing workflows were respected, allowing for seamless integration of RT-Labs’ software solutions.
The PDU included CAN communication and advanced power I/O features & diagnostics, addressing the specific demands of the VERA project. The VCM, with its high complexity, served as a communications hub and central control system, enabling precise vehicle operation and route calculation. Volvo’s existing workflows were respected, allowing for seamless integration of RT-Labs’ software solutions.
The Result
RT-Labs delivered fully functional PDU and VCM prototypes on time for the Berlin trade show. Both systems operated flawlessly, impressing stakeholders and demonstrating the feasibility of Volvo’s autonomous vision. Following the event, Volvo decided to adopt the PDU design for one of their Battery Electric Vehicle (BEV) line, and the VCM was integrated into Volvo VCE’s TARA under the name AVCM, making it a cornerstone of their electric and autonomous vehicle strategy.
The success of this collaboration highlighted the efficiency of RT-Labs’ rapid development process, their ability to integrate with complex workflows, and their commitment to delivering under tight deadlines. The project not only showcased innovation but also reinforced Volvo’s position as a leader in sustainable and autonomous transport solutions.
Press release from AB Volvo: https://www.volvogroup.com/en/news-and-media/news/2019/jun/news-3336083.html