Interconnect yield analysis and fault tolerance for field programmable gate arrays

Imperial Users onl

Characterization of Interconnection Delays in FPGAS Due to Single Event Upsets and Mitigation

RÉSUMÉ L’utilisation incessante de composants électroniques à géométrie toujours plus faible a engendré de nouveaux défis au fil des ans. Par exemple, des semi-conducteurs à mémoire et à microprocesseur plus avancés sont utilisés dans les systèmes avioniques qui présentent une susceptibilité importante aux phénomènes de rayonnement cosmique. L'une des principales implications des rayons cosmiques, observée principalement dans les satellites en orbite, est l'effet d'événements singuliers (SEE). Le rayonnement atmosphérique suscite plusieurs préoccupations concernant la sécurité et la fiabilité de l'équipement avionique, en particulier pour les systèmes qui impliquent des réseaux de portes programmables (FPGA). Les FPGA à base de cellules de mémoire statique (SRAM) présentent une solution attrayante pour mettre en oeuvre des systèmes complexes dans le domaine de l’avionique. Les expériences de rayonnement réalisées sur les FPGA ont dévoilé la vulnérabilité de ces dispositifs contre un type particulier de SEE, à savoir, les événements singuliers de changement d’état (SEU). Un SEU est considérée comme le changement de l'état d'un élément bistable (c'est-à-dire, un bit-flip) dû à l'effet d'un ion, d'un proton ou d’un neutron énergétique. Cet effet est non destructif et peut être corrigé en réécrivant la partie de la SRAM affectée. Les changements de délai (DC) potentiels dus aux SEU affectant la mémoire de configuration de routage ont été récemment confirmés. Un des objectifs de cette thèse consiste à caractériser plus précisément les DC dans les FPGA causés par les SEU. Les DC observés expérimentalement sont présentés et la modélisation au niveau circuit de ces DC est proposée. Les circuits impliqués dans la propagation du délai sont validés en effectuant une modélisation précise des blocs internes à l'intérieur du FPGA et en exécutant des simulations. Les résultats montrent l’origine des DC qui sont en accord avec les mesures expérimentales de délais. Les modèles proposés au niveau circuit sont, aux meilleures de notre connaissance, le premier travail qui confirme et explique les délais combinatoires dans les FPGA. La conception d'un circuit moniteur de délai pour la détection des DC a été faite dans la deuxième partie de cette thèse. Ce moniteur permet de détecter un changement de délai sur les sections critiques du circuit et de prévenir les pannes de synchronisation engendrées par les SEU sans utiliser la redondance modulaire triple (TMR).----------ABSTRACT The unrelenting demand for electronic components with ever diminishing feature size have emerged new challenges over the years. Among them, more advanced memory and microprocessor semiconductors are being used in avionic systems that exhibit a substantial susceptibility to cosmic radiation phenomena. One of the main implications of cosmic rays, which was primarily observed in orbiting satellites, is single-event effect (SEE). Atmospheric radiation causes several concerns regarding the safety and reliability of avionics equipment, particularly for systems that involve field programmable gate arrays (FPGA). SRAM-based FPGAs, as an attractive solution to implement systems in aeronautic sector, are very susceptible to SEEs in particular Single Event Upset (SEU). An SEU is considered as the change of the state of a bistable element (i.e., bit-flip) due to the effect of an energetic ion or proton. This effect is non-destructive and may be fixed by rewriting the affected part. Sensitivity evaluation of SRAM-based FPGAs to a physical impact such as potential delay changes (DC) has not been addressed thus far in the literature. DCs induced by SEU can affect the functionality of the logic circuits by disturbing the race condition on critical paths. The objective of this thesis is toward the characterization of DCs in SRAM-based FPGAs due to transient ionizing radiation. The DCs observed experimentally are presented and the circuit-level modeling of those DCs is proposed. Circuits involved in delay propagation are reverse-engineered by performing precise modeling of internal blocks inside the FPGA and executing simulations. The results show the root cause of DCs that are in good agreement with experimental delay measurements. The proposed circuit level models are, to the best of our knowledge, the first work on modeling of combinational delays in FPGAs.In addition, the design of a delay monitor circuit for DC detection is investigated in the second part of this thesis. This monitor allowed to show experimentally cumulative DCs on interconnects in FPGA. To this end, by avoiding the use of triple modular redundancy (TMR), a mitigation technique for DCs is proposed and the system downtime is minimized. A method is also proposed to decrease the clock frequency after DC detection without interrupting the process

FPGA ARCHITECTURE AND VERIFICATION OF BUILT IN SELF-TEST (BIST) FOR 32-BIT ADDER/SUBTRACTER USING DE0-NANO FPGA AND ANALOG DISCOVERY 2 HARDWARE

The integrated circuit (IC) is an integral part of everyday modern technology, and its application is very attractive to hardware and software design engineers because of its versatility, integration, power consumption, cost, and board area reduction. IC is available in various types such as Field Programming Gate Array (FPGA), Application Specific Integrated Circuit (ASIC), System on Chip (SoC) architecture, Digital Signal Processing (DSP), microcontrollers (μC), and many more. With technology demand focused on faster, low power consumption, efficient IC application, design engineers are facing tremendous challenges in developing and testing integrated circuits that guaranty functionality, high fault coverage, and reliability as the transistor technology is shrinking to the point where manufacturing defects of ICs are affecting yield which associates with the increased cost of the part. The competitive IC market is pressuring manufactures of ICs to develop and market IC in a relatively quick turnaround which in return requires design and verification engineers to develop an integrated self-test structure that would ensure fault-free and the quality product is delivered on the market. 70-80% of IC design is spent on verification and testing to ensure high quality and reliability for the enduser. To test complex and sophisticated IC designs, the verification engineers must produce laborious and costly test fixtures which affect the cost of the part on the competitive market. To avoid increasing the part cost due to yield and test time to the end-user and to keep up with the competitive market many IC design engineers are deviating from complex external test fixture approach and are focusing on integrating Built-in Self-Test (BIST) or Design for Test (DFT) techniques onto IC’s which would reduce time to market but still guarantee high coverage for the product. Understanding the BIST, the architecture, as well as the application of IC, must be understood before developing IC. The architecture of FPGA is elaborated in this paper followed by several BIST techniques and applications of those BIST relative to FPGA, SoC, analog to digital (ADC), or digital to analog converters (DAC) that are integrated on IC. Paper is concluded with verification of BIST for the 32-bit adder/subtracter designed in Quartus II software using the Analog Discovery 2 module as stimulus and DE0-NANO FPGA board for verification

Analysis and Evaluation of PUF-based SoC Designs for Security Applications

This paper presents a critical analysis and statistical evaluation of two categories of Physically Unclonable Functions (PUFs): ring oscillator PUF and a new proposed adapted latch based PUF. The main contribution is that of measuring the properties of PUF which provide the basic information for using them in security applications. The original method involved the conceptual design of adapted latch based PUFs and ring oscillator PUFs in combination with peripheral devices in order to create an environment for experimental analysis of PUF properties. Implementation, testing and analysis of results followed. This approach has applications on high level security

Evaluation of advanced techniques for structural FPGA self-test

This thesis presents a comprehensive test generation framework for FPGA logic elements and interconnects. It is based on and extends the current state-of-the-art. The purpose of FPGA testing in this work is to achieve reliable reconfiguration for a FPGA-based runtime reconfigurable system. A pre-configuration test is performed on a portion of the FPGA before it is reconfigured as part of the system to ensure that the FPGA fabric is fault-free. The implementation platform is the Xilinx Virtex-5 FPGA family. Existing literature in FPGA testing is evaluated and reviewed thoroughly. The various approaches are compared against one another qualitatively and the approach most suitable to the target platform is chosen. The array testing method is employed in testing the FPGA logic for its low hardware overhead and optimal test time. All tests are additionally pipelined to reduce test application time and use a high test clock frequency. A hybrid fault model including both structural and functional faults is assumed. An algorithm for the optimization of the number of required FPGA test configurations is developed and implemented in Java using a pseudo-random set-covering heuristic. Optimal solutions are obtained for Virtex-5 logic slices. The algorithm effort is parameterizable with the number of loop iterations each of which take approximately one second for a Virtex-5 sliceL circuit. A flexible test architecture for interconnects is developed. Arbitrary wire types can be tested in the same test configuration with no hardware overhead. Furthermore, a routing algorithm is integrated with the test template generation to select the wires under test and route them appropriately. Nine test configurations are required to achieve full test coverage for the FPGA logic. For interconnect testing, a local router-based on depth-first graph traversal is implemented in Java as the basis for creating systematic interconnect test templates. Pent wire testing is additionally implemented as a proof of concept. The test clock frequency for all tests exceeds 170 MHz and the hardware overhead is always lower than seven CLBs. All implemented tests are parameterizable such that they can be applied to any portion of the FPGA regardless of size or position

Using Relocatable Bitstreams for Fault Tolerance

This research develops a method for relocating reconfigurable modules on the Virtex-II (Pro) family of Field Programmable Gate Arrays (FPGAs). A bitstream translation program is developed which correctly changes the location of a partial bitstream that implements a module on the FPGA. To take advantage of relocatable modules, three fault-tolerance circuit designs are developed and tested. This circuit can operate through a fault by efficiently removing the faulty module and replacing it with a relocated module without faults. The FPGA can recover from faults at a known location, without the need for external intervention using an embedded fault recovery system. The recovery system uses an internal PowerPC to relocate the modules and reprogram the FPGA. Due to the limited architecture of the target FPGA and Xilinx tool errors, an FPGA with automatic fault recovery could not be demonstrated. However, the various components needed to do this type of recovery have been implemented and demonstrated individually

Via-switch FPGA with transistor-free programmability enabling energy-efficient near-memory parallel computation

We are developing field-programmable gate arrays (FPGAs) with a new non-volatile switch called via-switch. In via-switch FPGAs (VS-FPGAs), the via-switches required for reconfiguration are placed in the routing layer so that the entire transistor layer can be utilized for computing, and higher implementation density can be achieved compared to conventional SRAM FPGAs. Furthermore, since arithmetic units and memories for computing can be placed under the via-switch crossbar for routing, large-scale parallel operations can be realized where the memory and the arithmetic unit are adjacent to each other. These features enable operation with high energy efficiency. This article reports 65 nm prototype fabrication results and predicted the performance of the VS-FPGA designed for AI applications. We also present the developed application mapping flow and crossbar programming method. The VS-FPGA closes the gap between FPGA and application-specific integrated circuits (ASIC) with the performance advantage of the via-switch and via-switch copy scheme for FPGA-to-ASIC migration, contributing to the expansion of the FPGA usage

Développement des techniques de test et de diagnostic pour les FPGA hiérarchique de type mesh

The evolution trend of shrinking feature size and increasing complexity in modern electronics is being slowed down due to physical limits that generate numerous imperfections and defects during fabrication steps or projected life time of the chip. Field Programmable Gate Arrays (FPGAs) are used in complex digital systems mainly due to their reconfigurability and shorter time-to-market. To maintain a high reliability of such systems, FPGAs should be tested thoroughly for defects. FPGA architecture optimization for area saving and better signal routability is an ongoing process which directly impacts the overall FPGA testability, hence the reliability. This thesis presents a complete strategy for test and diagnosis of manufacturing defects in mesh-based FPGAs containing a novel multilevel interconnects topology which promises to provide better area and routability. Efficiency of the proposed test schemes is analyzed in terms of test cost, respective fault coverage and diagnostic resolution.L’évolution tendant à réduire la taille et augmenter la complexité des circuits électroniques modernes, est en train de ralentir du fait des limitations technologiques, qui génèrent beaucoup de d’imperfections et de defaults durant la fabrication ou la durée de vie de la puce. Les FPGAs sont utilisés dans les systèmes numériques complexes, essentiellement parce qu’ils sont reconfigurables et rapide à commercialiser. Pour garder une grande fiabilité de tels systèmes, les FPGAs doivent être testés minutieusement pour les defaults. L’optimisation de l’architecture des FPGAs pour l’économie de surface et une meilleure routabilité est un processus continue qui impacte directement la testabilité globale et de ce fait, la fiabilité. Cette thèse présente une stratégie complète pour le test et le diagnostique des defaults de fabrication des “mesh-based FPGA” contenant une nouvelle topologie d’interconnections à plusieurs niveaux, ce qui promet d’apporter une meilleure routabilité. Efficacité des schémas proposes est analysée en termes de temps de test, couverture de faute et résolution de diagnostique

Design Disjunction for Resilient Reconfigurable Hardware

Contemporary reconfigurable hardware devices have the capability to achieve high performance, power efficiency, and adaptability required to meet a wide range of design goals. With scaling challenges facing current complementary metal oxide semiconductor (CMOS), new concepts and methodologies supporting efficient adaptation to handle reliability issues are becoming increasingly prominent. Reconfigurable hardware and their ability to realize self-organization features are expected to play a key role in designing future dependable hardware architectures. However, the exponential increase in density and complexity of current commercial SRAM-based field-programmable gate arrays (FPGAs) has escalated the overhead associated with dynamic runtime design adaptation. Traditionally, static modular redundancy techniques are considered to surmount this limitation; however, they can incur substantial overheads in both area and power requirements. To achieve a better trade-off among performance, area, power, and reliability, this research proposes design-time approaches that enable fine selection of redundancy level based on target reliability goals and autonomous adaptation to runtime demands. To achieve this goal, three studies were conducted: First, a graph and set theoretic approach, named Hypergraph-Cover Diversity (HCD), is introduced as a preemptive design technique to shift the dominant costs of resiliency to design-time. In particular, union-free hypergraphs are exploited to partition the reconfigurable resources pool into highly separable subsets of resources, each of which can be utilized by the same synthesized application netlist. The diverse implementations provide reconfiguration-based resilience throughout the system lifetime while avoiding the significant overheads associated with runtime placement and routing phases. Evaluation on a Motion-JPEG image compression core using a Xilinx 7-series-based FPGA hardware platform has demonstrated the potential of the proposed FT method to achieve 37.5% area saving and up to 66% reduction in power consumption compared to the frequently-used TMR scheme while providing superior fault tolerance. Second, Design Disjunction based on non-adaptive group testing is developed to realize a low-overhead fault tolerant system capable of handling self-testing and self-recovery using runtime partial reconfiguration. Reconfiguration is guided by resource grouping procedures which employ non-linear measurements given by the constructive property of f-disjunctness to extend runtime resilience to a large fault space and realize a favorable range of tradeoffs. Disjunct designs are created using the mosaic convergence algorithm developed such that at least one configuration in the library evades any occurrence of up to d resource faults, where d is lower-bounded by f. Experimental results for a set of MCNC and ISCAS benchmarks have demonstrated f-diagnosability at the individual slice level with average isolation resolution of 96.4% (94.4%) for f=1 (f=2) while incurring an average critical path delay impact of only 1.49% and area cost roughly comparable to conventional 2-MR approaches. Finally, the proposed Design Disjunction method is evaluated as a design-time method to improve timing yield in the presence of large random within-die (WID) process variations for application with a moderately high production capacity