Autonomous Solutions
Autonomous Solutions
As Volvo Autonomous Solutions (V.A.S.) continues autonomous operations with customers like DHL, and Aurora validates its technology for driverless operations, the partnership stands ready to achieve one of its greatest milestones yet—industrializing a complex autonomous solution at scale.
The collaboration between V.A.S. and Aurora, which began in 2021, is centered on co-developing a deeply integrated solution: the Volvo VNL Autonomous powered by the Aurora Driver, an SAE L4 autonomous driving system.
Combining Volvo’s proven safety expertise and manufacturing capabilities with Aurora’s innovative self-driving technology has created a safe, efficient, and scalable autonomous solution. While the final product may appear straightforward, achieving it requires managing significant complexity across design, production processes, quality standards, and supply chain resilience.
The path to industrialization begins with aligning the design of the Volvo VNL Autonomous and the Aurora Driver. This alignment relies on a shared vision, mutual trust, and close collaboration throughout development.
While Volvo takes responsibility for the truck’s overall design, Aurora leads the Aurora Driver development. Collaboration is essential, especially when aligning critical hardware and software interfaces. Through constant knowledge sharing—such as demonstrating proper hardware installation techniques and advising on tested components—the teams achieve deep integration crucial for safe autonomous operation.
“Our relationship with Aurora is different from other suppliers,” says Henrik Häggström, Head of Purchasing at Volvo Autonomous Solutions. “It’s more of a partnership built on co-development, where different areas of expertise complement and support one another to form a unique solution.”
Trust is critical in this partnership. “Volvo is the expert in trucks, and we bring the self-driving expertise,” explains Kelsey Abdollahian, Technical Program Manager of Manufacturing and Supply at Aurora. “We have clearly defined areas of responsibility, including interfaces between our systems. We trust each other to do what we each do best and then have joint reviews and approvals to ensure we’re united on the final product.”
Quality checks and validations for hardware components begin long before production starts. The Design and Process Failure Mode and Effect Analyses (DFMEA and PFMEA, respectively) identify potential issues early on, allowing preventive measures to be implemented well ahead of assembly. For example, a comprehensive process to develop, test, and validate sensor pods is done before they're fitted to the truck's roof, significantly reducing risks and avoiding costly rework. “We share our expertise and experience with the Aurora Driver kit, but when it comes to the production line, Volvo has the ultimate authority for how the truck is put together,” says Kelsey.
Both V.A.S. and Aurora follow rigorous global automotive quality standards. Volvo uses standards to ensure consistent quality during mass production, while Production Part Approval Processes (PPAP) are conducted with suppliers to ensure components meet strict specifications. Volvo also supports Aurora in implementing similar quality assurance measures for the Aurora Driver’s hardware components.
“To ensure consistently high quality, every piece of hardware and software is held to strict criteria. This ensures that all elements meet mutual requirements,” explains Henrik. “For V.A.S., international automotive standards are used as a baseline to ensure consistent quality in mass production. We have also agreed different proof points together with our supply chain partners regarding test verification and validation. General audits are carried out before any stages are finalized and any production begins. Production Part Approval Processes (PPAP) are also carried out on our suppliers and on the redundant base truck.”
Although V.A.S. doesn't directly manage Aurora Driver hardware production, it provides essential support—assisting with supplier audits and pre-inspections to ensure high-quality outcomes.
The Volvo VNL Autonomous incorporates nearly two hundred additional components for redundancy to ensure safe autonomous operations, while the Aurora Driver consists of a centralized computing unit, sensor pods, cleaning systems, microphones, antennas, and optimized wiring solutions.
Despite the increased complexity compared to traditional trucks, Volvo and Aurora are preparing for efficient production. Aurora, for example, consolidates components into modular units, enabling easier integration.
“Aurora consolidated numerous components into a small number of integrated modules which allows OEMs to integrate a discrete number of parts into their truck and find the best way to fit it into their assembly line,” adds Kelsey. The focus on simplification saves valuable time, reduces complexity, and eases assembly.
Initial production will take place at Volvo’s advanced pilot plant at New River Valley, the largest Volvo Trucks production facility in the United States, offering a controlled environment to refine integration processes, calibration, and testing.
By utilizing the pilot plant, Volvo and Aurora benefit from the advantages of traditional manufacturing, such as standardized tools and processes, while gaining additional flexibility for process validation.
“When it comes to hardware requirements, the pilot plant helps us optimize how to logistically get parts into the factory. It also gives us the chance to carry out calibration and end-of-line testing, which we can potentially learn from. The main production line will be extremely sophisticated, so the pilot plant gives a unique opportunity to test and optimize our processes without the risk – saving time and ensuring quality and safety,” Henrik says.
Production on the main line, where autonomous trucks are built at the same rate as standard trucks, commences with the future generation of the Aurora Driver manufactured by Continental in a couple of years.
Introducing new hardware to the market is complex and time-intensive, often taking years from initial design to the start of production. Recognizing this challenge early on, Aurora teamed up with Continental to develop a reliable, serviceable, cost-efficient Aurora Driver hardware kit for mass production.
Continental plans to start manufacturing the Aurora Driver hardware in 2027, which will then be shipped to Volvo for integration into the Volvo VNL Autonomous. With Continental's automotive development and manufacturing expertise, the future Aurora Driver will be designed to deliver customer value for one million miles.
“Continental has been involved from an early stage where they’ve been applying their design-for-manufacturing knowledge to make the Aurora Driver scalable and OEM agnostic,” says Kelsey. “They're also identifying the risky supply chain parts we need to get ahead of.” This collaboration ensures that the Aurora Driver hardware can be seamlessly integrated into Volvo’s assembly line.
Volvo is also enhancing supply chain resilience, a key component of mass production readiness.
“As well as building redundancy into our trucks, we have also built it into our supply chain,” explains Henrik. “We try to ensure that we have a secondary source for the components we need. Of course, having such a unique product will always present challenges, but we strive to ensure our supply chain is as resilient and reliable as possible.”
Through rigorous alignment of industry-leading processes and quality standards, Volvo Autonomous Solutions and Aurora have developed a scalable, sophisticated autonomous solution with safety built-in from the start. This partnership embodies technical excellence and a shared vision—promising to transform logistics and shape the future of transportation.
