Special session: Hot topics: Statistical test methods

International audienceThe process of testing Integrated Circuits involves a huge amount of data: electrical circuit measurements, information from wafer process monitors, spatial location of the dies, wafer lot numbers, etc. In addition, the relationships between faults, process variations and circuit performance are likely to be very complex and non-linear. Test (and its extension to diagnosis) should be considered as a challenging highly dimensional multivariate problem.Advanced statistical data processing offers a powerful set of tools, borrowed from the fields of data mining, machine learning or artificial intelligence, to get the most out of this data. Indeed, these mathematical tools have opened a number of novel and interesting research lines within the field of IC testing.In this special session, prominent researchers in this field will share their views on this topic and present some of their last findings. The first talk will discuss the interest of likelihood prevalence in random fault simulation. The second talk will show how statistical data analysis can help diagnosing test efficiency. The third talk will deal with the reliability of Alternate Test of AMS-RF circuits. The fourth and last talk will address the idea of mining the test data for improving design manufacturing and even test itself

Infrastructures and Algorithms for Testable and Dependable Systems-on-a-Chip

Every new node of semiconductor technologies provides further miniaturization and higher performances, increasing the number of advanced functions that electronic products can offer. Silicon area is now so cheap that industries can integrate in a single chip usually referred to as System-on-Chip (SoC), all the components and functions that historically were placed on a hardware board. Although adding such advanced functionality can benefit users, the manufacturing process is becoming finer and denser, making chips more susceptible to defects. Today’s very deep-submicron semiconductor technologies (0.13 micron and below) have reached susceptibility levels that put conventional semiconductor manufacturing at an impasse. Being able to rapidly develop, manufacture, test, diagnose and verify such complex new chips and products is crucial for the continued success of our economy at-large. This trend is expected to continue at least for the next ten years making possible the design and production of 100 million transistor chips. To speed up the research, the National Technology Roadmap for Semiconductors identified in 1997 a number of major hurdles to be overcome. Some of these hurdles are related to test and dependability. Test is one of the most critical tasks in the semiconductor production process where Integrated Circuits (ICs) are tested several times starting from the wafer probing to the end of production test. Test is not only necessary to assure fault free devices but it also plays a key role in analyzing defects in the manufacturing process. This last point has high relevance since increasing time-to-market pressure on semiconductor fabrication often forces foundries to start volume production on a given semiconductor technology node before reaching the defect densities, and hence yield levels, traditionally obtained at that stage. The feedback derived from test is the only way to analyze and isolate many of the defects in today’s processes and to increase process’s yield. With the increasing need of high quality electronic products, at each new physical assembly level, such as board and system assembly, test is used for debugging, diagnosing and repairing the sub-assemblies in their new environment. Similarly, the increasing reliability, availability and serviceability requirements, lead the users of high-end products performing periodic tests in the field throughout the full life cycle. To allow advancements in each one of the above scaling trends, fundamental changes are expected to emerge in different Integrated Circuits (ICs) realization disciplines such as IC design, packaging and silicon process. These changes have a direct impact on test methods, tools and equipment. Conventional test equipment and methodologies will be inadequate to assure high quality levels. On chip specialized block dedicated to test, usually referred to as Infrastructure IP (Intellectual Property), need to be developed and included in the new complex designs to assure that new chips will be adequately tested, diagnosed, measured, debugged and even sometimes repaired. In this thesis, some of the scaling trends in designing new complex SoCs will be analyzed one at a time, observing their implications on test and identifying the key hurdles/challenges to be addressed. The goal of the remaining of the thesis is the presentation of possible solutions. It is not sufficient to address just one of the challenges; all must be met at the same time to fulfill the market requirements

Methods for testing of analog circuits

Práce se zabývá metodami pro testování lineárních analogových obvodů v kmitočtové oblasti. Cílem je navrhnout efektivní metody pro automatické generování testovacího plánu. Snížením počtu měření a výpočetní náročnosti lze výrazně snížit náklady za testování. Práce se zabývá multifrekveční parametrickou poruchovou analýzou, která byla plně implementována do programu Matlab. Vhodnou volbou testovacích kmitočtů lze potlačit chyby měření a chyby způsobené výrobními tolerancemi obvodových prvků. Navržené metody pro optimální volbu kmitočtů byly statisticky ověřeny metodou MonteCarlo. Pro zvýšení přesnosti a snížení výpočetní náročnosti poruchové analýzy byly vyvinuty postupy založené na metodě nejmenších čtverců a přibližné symbolické analýze.The thesis deals with methods for testing of linear analog circuits in the frequency domain. The goal is to develop new efficient methods for automatic test plan generation. To reduce test costs a minimum number of measurements as well as less computational demands are the fundamental aims. The thesis is focused on the multi-frequency parametric fault diagnosis which was fully implemented in the Matlab program. The fundamental problem consists in selection of test frequencies which can reduce the influences of measurement errors and errors caused by tolerances of well-working components. The proposed methods for test frequency selection were statistically verified by the MonteCarlo method. To improve the accuracy and reduce the computational complexity of fault diagnosis, the methods based on least-square techniques and approximate symbolic analysis were presented.

The implementation and applications of multiple-valued logic

Multiple-Valued Logic (MVL) takes two major forms. Multiple-valued circuits can implement the logic directly by using multiple-valued signals, or the logic can be implemented indirectly with binary circuits, by using more than one binary signal to represent a single multiple-valued signal. Techniques such as carry-save addition can be viewed as indirectly implemented MVL. Both direct and indirect techniques have been shown in the past to provide advantages over conventional arithmetic and logic techniques in algorithms required widely in computing for applications such as image and signal processing. It is possible to implement basic MVL building blocks at the transistor level. However, these circuits are difficult to design due to their non binary nature. In the design stage they are more like analogue circuits than binary circuits. Current integrated circuit technologies are biased towards binary circuitry. However, in spite of this, there is potential for power and area savings from MVL circuits, especially in technologies such as BiCMOS. This thesis shows that the use of voltage mode MVL will, in general not provide bandwidth increases on circuit buses because the buses become slower as the number of signal levels increases. Current mode MVL circuits however do have potential to reduce power and area requirements of arithmetic circuitry. The design of transistor level circuits is investigated in terms of a modern production technology. A novel methodology for the design of current mode MVL circuits is developed. The methodology is based upon the novel concept of the use of non-linear current encoding of signals, providing the opportunity for the efficient design of many previously unimplemented circuits in current mode MVL. This methodology is used to design a useful set of basic MVL building blocks, and fabrication results are reported. The creation of libraries of MVL circuits is also discussed. The CORDIC algorithm for two dimensional vector rotation is examined in detail as an example for indirect MVL implementation. The algorithm is extended to a set of three dimensional vector rotators using conventional arithmetic, redundant radix four arithmetic, and Taylor's series expansions. These algorithms can be used for two dimensional vector rotations in which no scale factor corrections are needed. The new algorithms are compared in terms of basic VLSI criteria against previously reported algorithms. A pipelined version of the redundant arithmetic algorithm is floorplanned and partially laid out to give indications of wiring overheads, and layout densities. An indirectly implemented MVL algorithm such as the CORDIC algorithm described in this thesis would clearly benefit from direct implementation in MVL

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

Ultra Reliable Computing Systems

For high security and safety applications as well as general purpose applications, it is necessary to have ultra reliable computing systems. This dissertation describes our system of self-testable and self-repairable digital devices, especially, EPLDs (Electrically Programmable Logic Devices). In addition to significantly improving the reliability of digital systems, our self-healing and re-configurable system design with added repair capability can also provide higher yields, lower testing costs, and faster time-to-market for the semiconductor industry. The digital system in our approach is composed of blocks, which realize combinational and sequential circuits using GALs (Generic Array Logic Devices). We describe three techniques for fault-locating and fault-repairing in these devices. The methodology we used for evaluation of these methods and a comparison with devices that have no self-repair capability was simulation of the self-repair algorithms. Our simulations show that the lifetime for a GAL-based EPLD that uses our multiple self-repairing methods is longer than the lifetime of a GAL-based EPLD that uses a single self-repair method or no self-repair method. Specifically, our work demonstrates that the lifetime of a GAL can be increased by adding extra columns in the AND array of a GAL and extra output ORs in a GAL. It also gives information on how many extra columns and extra ORs a GAL needs and which self-repairing method should be used to guarantee a given lifetime. Thus, we can estimate an ideal point, where the maximum reliability can be reached with the minimum cost

Built-in tests for a real-time embedded system.

Thesis (M.Sc.)-University of Natal, Durban, 1991.Beneath the facade of the applications code of a well-designed real-time embedded system lies intrinsic firmware that facilitates a fast and effective means of detecting and diagnosing inevitable hardware failures. These failures can encumber the availability of a system, and, consequently, an identification of the source of the malfunction is needed. It is shown that the number of possible origins of all manner of failures is immense. As a result, fault models are contrived to encompass prevalent hardware faults. Furthermore, the complexity is reduced by determining syndromes for particular circuitry and applying test vectors at a functional block level. Testing phases and philosophies together with standardisation policies are defined to ensure the compliance of system designers to the underlying principles of evaluating system integrity. The three testing phases of power-on self tests at system start up, on-line health monitoring and off-line diagnostics are designed to ensure that the inherent test firmware remains inconspicuous during normal applications. The prominence of the code is, however, apparent on the detection or diagnosis of a hardware failure. The authenticity of the theoretical models, standardisation policies and built-in test philosophies are illustrated by means of their application to an intricate real-time system. The architecture and the software design implementing the idealogies are described extensively. Standardisation policies, enhanced by the proposition of generic tests for common core components, are advocated at all hierarchical levels. The presentation of the integration of the hardware and software are aimed at portraying the moderately complex nature of the task of generating a set of built-in tests for a real-time embedded system. In spite of generic policies, the intricacies of the architecture are found to have a direct influence on software design decisions. It is thus concluded that the diagnostic objectives of the user requirements specification be lucidly expressed by both operational and maintenance personnel for all testing phases. Disparity may exist between the system designer and the end user in the understanding of the requirements specification defining the objectives of the diagnosis. It is thus essential for complete collaboration between the two parties throughout the development life cycle, but especially during the preliminary design phase. Thereafter, the designer would be able to decide on the sophistication of the system testing capabilities

Low-cost and efficient fault detection and diagnosis schemes for modern cores

Continuous improvements in transistor scaling together with microarchitectural advances have made possible the widespread adoption of high-performance processors across all market segments. However, the growing reliability threats induced by technology scaling and by the complexity of designs are challenging the production of cheap yet robust systems. Soft error trends are haunting, especially for combinational logic, and parity and ECC codes are therefore becoming insufficient as combinational logic turns into the dominant source of soft errors. Furthermore, experts are warning about the need to also address intermittent and permanent faults during processor runtime, as increasing temperatures and device variations will accelerate inherent aging phenomena. These challenges specially threaten the commodity segments, which impose requirements that existing fault tolerance mechanisms cannot offer. Current techniques based on redundant execution were devised in a time when high penalties were assumed for the sake of high reliability levels. Novel light-weight techniques are therefore needed to enable fault protection in the mass market segments. The complexity of designs is making post-silicon validation extremely expensive. Validation costs exceed design costs, and the number of discovered bugs is growing, both during validation and once products hit the market. Fault localization and diagnosis are the biggest bottlenecks, magnified by huge detection latencies, limited internal observability, and costly server farms to generate test outputs. This thesis explores two directions to address some of the critical challenges introduced by unreliable technologies and by the limitations of current validation approaches. We first explore mechanisms for comprehensively detecting multiple sources of failures in modern processors during their lifetime (including transient, intermittent, permanent and also design bugs). Our solutions embrace a paradigm where fault tolerance is built based on exploiting high-level microarchitectural invariants that are reusable across designs, rather than relying on re-execution or ad-hoc block-level protection. To do so, we decompose the basic functionalities of processors into high-level tasks and propose three novel runtime verification solutions that combined enable global error detection: a computation/register dataflow checker, a memory dataflow checker, and a control flow checker. The techniques use the concept of end-to-end signatures and allow designers to adjust the fault coverage to their needs, by trading-off area, power and performance. Our fault injection studies reveal that our methods provide high coverage levels while causing significantly lower performance, power and area costs than existing techniques. Then, this thesis extends the applicability of the proposed error detection schemes to the validation phases. We present a fault localization and diagnosis solution for the memory dataflow by combining our error detection mechanism, a new low-cost logging mechanism and a diagnosis program. Selected internal activity is continuously traced and kept in a memory-resident log whose capacity can be expanded to suite validation needs. The solution can catch undiscovered bugs, reducing the dependence on simulation farms that compute golden outputs. Upon error detection, the diagnosis algorithm analyzes the log to automatically locate the bug, and also to determine its root cause. Our evaluations show that very high localization coverage and diagnosis accuracy can be obtained at very low performance and area costs. The net result is a simplification of current debugging practices, which are extremely manual, time consuming and cumbersome. Altogether, the integrated solutions proposed in this thesis capacitate the industry to deliver more reliable and correct processors as technology evolves into more complex designs and more vulnerable transistors.El continuo escalado de los transistores junto con los avances microarquitectónicos han posibilitado la presencia de potentes procesadores en todos los segmentos de mercado. Sin embargo, varios problemas de fiabilidad están desafiando la producción de sistemas robustos. Las predicciones de "soft errors" son inquietantes, especialmente para la lógica combinacional: soluciones como ECC o paridad se están volviendo insuficientes a medida que dicha lógica se convierte en la fuente predominante de soft errors. Además, los expertos están alertando acerca de la necesidad de detectar otras fuentes de fallos (causantes de errores permanentes e intermitentes) durante el tiempo de vida de los procesadores. Los segmentos "commodity" son los más vulnerables, ya que imponen unos requisitos que las técnicas actuales de fiabilidad no ofrecen. Estas soluciones (generalmente basadas en re-ejecución) fueron ideadas en un tiempo en el que con tal de alcanzar altos nivel de fiabilidad se asumían grandes costes. Son por tanto necesarias nuevas técnicas que permitan la protección contra fallos en los segmentos más populares. La complejidad de los diseños está encareciendo la validación "post-silicon". Su coste excede el de diseño, y el número de errores descubiertos está aumentando durante la validación y ya en manos de los clientes. La localización y el diagnóstico de errores son los mayores problemas, empeorados por las altas latencias en la manifestación de errores, por la poca observabilidad interna y por el coste de generar las señales esperadas. Esta tesis explora dos direcciones para tratar algunos de los retos causados por la creciente vulnerabilidad hardware y por las limitaciones de los enfoques de validación. Primero exploramos mecanismos para detectar múltiples fuentes de fallos durante el tiempo de vida de los procesadores (errores transitorios, intermitentes, permanentes y de diseño). Nuestras soluciones son de un paradigma donde la fiabilidad se construye explotando invariantes microarquitectónicos genéricos, en lugar de basarse en re-ejecución o en protección ad-hoc. Para ello descomponemos las funcionalidades básicas de un procesador y proponemos tres soluciones de `runtime verification' que combinadas permiten una detección de errores a nivel global. Estas tres soluciones son: un verificador de flujo de datos de registro y de computación, un verificador de flujo de datos de memoria y un verificador de flujo de control. Nuestras técnicas usan el concepto de firmas y permiten a los diseñadores ajustar los niveles de protección a sus necesidades, mediante compensaciones en área, consumo energético y rendimiento. Nuestros estudios de inyección de errores revelan que los métodos propuestos obtienen altos niveles de protección, a la vez que causan menos costes que las soluciones existentes. A continuación, esta tesis explora la aplicabilidad de estos esquemas a las fases de validación. Proponemos una solución de localización y diagnóstico de errores para el flujo de datos de memoria que combina nuestro mecanismo de detección de errores, junto con un mecanismo de logging de bajo coste y un programa de diagnóstico. Cierta actividad interna es continuamente registrada en una zona de memoria cuya capacidad puede ser expandida para satisfacer las necesidades de validación. La solución permite descubrir bugs, reduciendo la necesidad de calcular los resultados esperados. Al detectar un error, el algoritmo de diagnóstico analiza el registro para automáticamente localizar el bug y determinar su causa. Nuestros estudios muestran un alto grado de localización y de precisión de diagnóstico a un coste muy bajo de rendimiento y área. El resultado es una simplificación de las prácticas actuales de depuración, que son enormemente manuales, incómodas y largas. En conjunto, las soluciones de esta tesis capacitan a la industria a producir procesadores más fiables, a medida que la tecnología evoluciona hacia diseños más complejos y más vulnerables