PowerCool: Simulation of Cooling and Powering of 3D MPSoCs with Integrated Flow Cell Arrays

Integrated Flow-Cell Arrays (FCAs) represent a combination of integrated liquid cooling and on-chip power generation, converting chemical energy of the flowing electrolyte solutions to electrical energy. The FCA technology provides a promising way to address both heat removal and power delivery issues in 3D Multiprocessor Systems-on-Chips (MPSoCs). In this paper we motivate the benefits of FCA in 3D MPSoCs via a qualitative analysis and explore the capabilities of the proposed technology using our extended PowerCool simulator. PowerCool is a tool that performs combined compact thermal and electrochemical simulation of 3D MPSoCs with inter-tier FCA-based cooling and power generation. We validate our electrochemical model against experimental data obtained using a micro-scale FCA, and extend PowerCool with a compact thermal model (3D-ICE) and subthreshold leakage estimation. We show the sensitivity of the FCA cooling and power generation on the design-time (FCA geometry) and run-time (fluid inlet temperature, flow rate) parameters. Our results show that we can optimize the FCA to keep maximum chip temperature below 95 °C for an average chip power consumption of 50 W/cm2 while generating up to 3.6 W per cm2 of chip area

GreenCool: An Energy-Efficient Liquid Cooling Design Technique for 3-D MPSoCs Via Channel Width Modulation

Liquid cooling using interlayer microchannels has appeared as a viable and scalable packaging technology for 3-D multiprocessor system-on-chips (MPSoCs). Microchannel-based liquid cooling, however, can substantially increase the on-chip thermal gradients, which are undesirable for reliability, performance, and cooling efficiency. In this paper, we present GreenCool, an optimal design methodology for liquid-cooled 3-D MPSoCs. GreenCool simultaneously minimizes the cooling energy for a given system while maintaining thermal gradients and peak temperatures under safe limits. This is accomplished by tuning the heat transfer characteristics of the microchannels using channel width modulation. Channel width modulation is compatible with the current process technologies and incurs minimal additional fabrication costs. Through an extensive set of experiments, we show that channel width modulation is capable of complementing and enhancing the benefits of temperature-aware floorplanning. We also experiment with a 16-core 3-D system with stacked dynamic random-access memory, for which GreenCool improves energy efficiency by up to 53% with respect to no channel modulation

Architectural-Physical Co-Design of 3D CPUs with Micro-Fluidic Cooling

The performance, energy efficiency and cost improvements due to traditional technology scaling have begun to slow down and present diminishing returns. Underlying reasons for this trend include fundamental physical limits of transistor scaling, the growing significance of quantum effects as transistors shrink, and a growing mismatch between transistors and interconnects regarding size, speed and power. Continued Moore's Law scaling will not come from technology scaling alone, and must involve improvements to design tools and development of new disruptive technologies such as 3D integration. 3D integration presents potential improvements to interconnect power and delay by translating the routing problem into a third dimension, and facilitates transistor density scaling independent of technology node. Furthermore, 3D IC technology opens up a new architectural design space of heterogeneously-integrated high-bandwidth CPUs. Vertical integration promises to provide the CPU architectures of the future by integrating high performance processors with on-chip high-bandwidth memory systems and highly connected network-on-chip structures. Such techniques can overcome the well-known CPU performance bottlenecks referred to as memory and communication wall. However the promising improvements to performance and energy efficiency offered by 3D CPUs does not come without cost, both in the financial investments to develop the technology, and the increased complexity of design. Two main limitations to 3D IC technology have been heat removal and TSV reliability. Transistor stacking creates increases in power density, current density and thermal resistance in air cooled packages. Furthermore the technology introduces vertical through silicon vias (TSVs) that create new points of failure in the chip and require development of new BEOL technologies. Although these issues can be controlled to some extent using thermal-reliability aware physical and architectural 3D design techniques, high performance embedded cooling schemes, such as micro-fluidic (MF) cooling, are fundamentally necessary to unlock the true potential of 3D ICs. A new paradigm is being put forth which integrates the computational, electrical, physical, thermal and reliability views of a system. The unification of these diverse aspects of integrated circuits is called Co-Design. Independent design and optimization of each aspect leads to sub-optimal designs due to a lack of understanding of cross-domain interactions and their impacts on the feasibility region of the architectural design space. Co-Design enables optimization across layers with a multi-domain view and thus unlocks new high-performance and energy efficient configurations. Although the co-design paradigm is becoming increasingly necessary in all fields of IC design, it is even more critical in 3D ICs where, as we show, the inter-layer coupling and higher degree of connectivity between components exacerbates the interdependence between architectural parameters, physical design parameters and the multitude of metrics of interest to the designer (i.e. power, performance, temperature and reliability). In this dissertation we present a framework for multi-domain co-simulation and co-optimization of 3D CPU architectures with both air and MF cooling solutions. Finally we propose an approach for design space exploration and modeling within the new Co-Design paradigm, and discuss the possible avenues for improvement of this work in the future

Electro-Thermal Codesign in Liquid Cooled 3D ICs: Pushing the Power-Performance Limits

The performance improvement of today's computer systems is usually accompanied by increased chip power consumption and system temperature. Modern CPUs dissipate an average of 70-100W power while spatial and temporal power variations result in hotspots with even higher power density (up to 300W/cm^2). The coming years will continue to witness a significant increase in CPU power dissipation due to advanced multi-core architectures and 3D integration technologies. Nowadays the problems of increased chip power density, leakage power and system temperatures have become major obstacles for further improvement in chip performance. The conventional air cooling based heat sink has been proved to be insufficient for three dimensional integrated circuits (3D-ICs). Hence better cooling solutions are necessary. Micro-fluidic cooling, which integrates micro-channel heat sinks into silicon substrates of the chip and uses liquid flow to remove heat inside the chip, is an effective active cooling scheme for 3D-ICs. While the micro-fluidic cooling provides excellent cooling to 3D-ICs, the associated overhead (cooling power consumed by the pump to inject the coolant through micro-channels) is significant. Moreover, the 3D-IC structure also imposes constraints on micro-channel locations (basically resource conflict with through-silicon-vias TSVs or other structures). In this work, we investigate optimized micro-channel configurations that address the aforementioned considerations. We develop three micro-channel structures (hotspot optimized cooling configuration, bended micro-channel and hybrid cooling network) that can provide sufficient cooling to 3D-IC with minimum cooling power overhead, while at the same time, compatible with the existing electrical structure such as TSVs. These configurations can achieve up to 70% cooling power savings compared with the configuration without any optimization. Based on these configurations, we then develop a micro-fluidic cooling based dynamic thermal management approach that maintains the chip temperature through controlling the fluid flow rate (pressure drop) through micro-channels. These cooling configurations are designed after the electrical parts, and therefore, compatible with the current standard IC design flow. Furthermore, the electrical, thermal, cooling and mechanical aspects of 3D-IC are interdependent. Hence the conventional design flow that designs the cooling configuration after electrical aspect is finished will result in inefficiencies. In order to overcome this problem, we then investigate electrical-thermal co-design methodology for 3D-ICs. Two co-design problems are explored: TSV assignment and micro-channel placement co-design, and gate sizing and fluidic cooling co-design. The experimental results show that the co-design enables a fundamental power-performance improvement over the conventional design flow which separates the electrical and cooling design. For example, the gate sizing and fluidic cooling co-design achieves 12% power savings under the same circuit timing constraint and 16% circuit speedup under the same power budget

Temperature-Aware Design and Management for 3D Multi-Core Architectures

Vertically-integrated 3D multiprocessors systems-on-chip (3D MPSoCs) provide the means to continue integrating more functionality within a unit area while enhancing manufacturing yields and runtime performance. However, 3D MPSoCs incur amplified thermal challenges that undermine the corresponding reliability. To address these issues, several advanced cooling technologies, alongside temperature-aware design-time optimizations and run-time management schemes have been proposed. In this monograph, we provide an overall survey on the recent advances in temperature-aware 3D MPSoC considerations. We explore the recent advanced cooling strategies, thermal modeling frameworks, design-time optimizations and run-time thermal management schemes that are primarily targeted for 3D MPSoCs. Our aim of proposing this survey is to provide a global perspective, highlighting the advancements and drawbacks on the recent state-of-the-ar

Improving processor efficiency through thermal modeling and runtime management of hybrid cooling strategies

One of the main challenges in building future high performance systems is the ability to maintain safe on-chip temperatures in presence of high power densities. Handling such high power densities necessitates novel cooling solutions that are significantly more efficient than their existing counterparts. A number of advanced cooling methods have been proposed to address the temperature problem in processors. However, tradeoffs exist between performance, cost, and efficiency of those cooling methods, and these tradeoffs depend on the target system properties. Hence, a single cooling solution satisfying optimum conditions for any arbitrary system does not exist. This thesis claims that in order to reach exascale computing, a dramatic improvement in energy efficiency is needed, and achieving this improvement requires a temperature-centric co-design of the cooling and computing subsystems. Such co-design requires detailed system-level thermal modeling, design-time optimization, and runtime management techniques that are aware of the underlying processor architecture and application requirements. To this end, this thesis first proposes compact thermal modeling methods to characterize the complex thermal behavior of cutting-edge cooling solutions, mainly Phase Change Material (PCM)-based cooling, liquid cooling, and thermoelectric cooling (TEC), as well as hybrid designs involving a combination of these. The proposed models are modular and they enable fast and accurate exploration of a large design space. Comparisons against multi-physics simulations and measurements on testbeds validate the accuracy of our models (resulting in less than 1C error on average) and demonstrate significant reductions in simulation time (up to four orders of magnitude shorter simulation times). This thesis then introduces temperature-aware optimization techniques to maximize energy efficiency of a given system as a whole (including computing and cooling energy). The proposed optimization techniques approach the temperature problem from various angles, tackling major sources of inefficiency. One important angle is to understand the application power and performance characteristics and to design management techniques to match them. For workloads that require short bursts of intense parallel computation, we propose using PCM-based cooling in cooperation with a novel Adaptive Sprinting technique. By tracking the PCM state and incorporating this information during runtime decisions, Adaptive Sprinting utilizes the PCM heat storage capability more efficiently, achieving 29\% performance improvement compared to existing sprinting policies. In addition to the application characteristics, high heterogeneity in on-chip heat distribution is an important factor affecting efficiency. Hot spots occur on different locations of the chip with varying intensities; thus, designing a uniform cooling solution to handle worst-case hot spots significantly reduces the cooling efficiency. The hybrid cooling techniques proposed as part of this thesis address this issue by combining the strengths of different cooling methods and localizing the cooling effort over hot spots. Specifically, the thesis introduces LoCool, a cooling system optimizer that minimizes cooling power under temperature constraints for hybrid-cooled systems using TECs and liquid cooling. Finally, the scope of this work is not limited to existing advanced cooling solutions, but it also extends to emerging technologies and their potential benefits and tradeoffs. One such technology is integrated flow cell array, where fuel cells are pumped through microchannels, providing both cooling and on-chip power generation. This thesis explores a broad range of design parameters including maximum chip temperature, leakage power, and generated power for flow cell arrays in order to maximize the benefits of integrating this technology with computing systems. Through thermal modeling and runtime management techniques, and by exploring the design space of emerging cooling solutions, this thesis provides significant improvements in processor energy efficiency.2018-07-09T00:00:00

Can Cooling Technology Save Many-Core Parallel Programming from Its Programming Woes?

An abstract of this work will be presented at the Compiler, Architecture and Tools Conference (CATC), Intel Development Center, Haifa, Israel November 23, 2015.This paper is advancing the following premise (henceforth, "vision"): that it is feasible to greatly enhance data movement in the short term, and do it in ways that would be both power efficient and pragmatic in the long term. The paper spells this premise out in greater detail: 1. it is feasible to build first generations of a variety of (power-inefficient) designs for which data movement will not be a restriction and begin application software development for them; 2. growing reliance on silicon compatible photonic technologies, and feasible advances in them with proper investment, will allow reduction of power consumption in these design by several orders of magnitude; 3. successful high performance application software, the ease of programming demonstrated and growing adoption by customers, software vendors and programmers will incentivize (hardware vendor) investment in new application-software-compatible generations of these designs (a new "software spiral" a la former Intel CEO, Andy Grove) with further reduction of power consumption in each generation; 4. microfluidic cooling is instrumental for enabling item 1, as well as for midwifing this overall vision. The opening paragraph of the paper provides a preamble to that vision, the body of the paper supports it and the paragraph "Moore's-Law-type vision" summarizes it. The scope of the paper is a bit forward looking and it may not exactly fit any particular community. However, its new directions for interaction among architecture and programming may suggest new horizons for representing and exposing a greater variety of data and task parallelism.National Science Foundatio

Thermal designs, models and optimization for three-dimensional integrated circuits

Three-dimensional integrated circuits (3D ICs), a novel packaging technology, are heavily studied to enable improved performance with denser packaging and reduced interconnects. Despite numerous advantages, thermal management is the biggest bottleneck to expanding the applications of this device stacking technology. In addition to implementing the thermal-aware designs of existing methodologies, it is necessary to implement new features to dissipate heat efficiently. This work presents two main aspects of thermal designs: on-chip level and package level. First, we propose a novel thermal-aware physical design on chip between devices. We aim to mitigate localized hotspots to ensure the functionality by adding thermal fin geometry to existing thermal through- silicon via (TTSV). We analyze design requirements of thermal fin for single TTSV as well as TTSV cluster designs with the goal of maximizing heat dissipation while minimizing the interference with routing and area consumption. An analytical model of the three-dimensional system and thermal resistance circuit is built for accurate and runtime-efficient thermal analysis. In terms of high-performance computing systems in 3D ICs, thermal bottle- necks are much more challenging with merely on-chip design solutions. Inter- tier liquid cooling microchannel layers have been introduced into 3D ICs as an integrated cooling mechanism to tackle the thermal degradation. Many existing research works optimize microchannel designs based on runtime-intensive numerical methods or inaccurate thermo-fluid models. Hence, we propose an accurate but compact closed-form model of tapered microchannel to capture the relationship between the channel geometry and heat transfer performance. To improve the accuracy, our correlations are based on the developing flow model and derived from numerical simulation data on a sub- set of multiple channel parameters. Our model achieves 57% less error in Nusselt number and 45 % less error in pressure drop for channels with inlet width 100-400 μm compared to a commonly used approximate model on fully developed flow. Next, we present the correlations for diverging channels as well as complete correlations that extend to any linearly tapering channel models, that include diverging shape, uniformly rectangular shape and converging shape. The complete models provide the flexibility to analyze and optimize any arbitrary geometry based on the piecewise linear channel wall assumption. Finally, we demonstrate the optimized channel designs using the derived correlations. Tapered channel models provided the flexibility to incorporate any arbitrary shapes and explore the advanced geometries during the optimization. The microchannel is divided into small segments in axial direction from inlet to outlet and piecewise optimized. The simulated annealing method is applied in our optimization, and channel width at one randomly chosen segment interface is altered to evaluate the design at each iteration. The objective is to minimize the overall thermal resistance while pressure drop is maintained less than a threshold value and channel widths have minimum and maximum boundaries. We compare the designs with the optimization based on fully developed flow models and verify the channel performance through numerical simulations. To guarantee optimality, accurate analysis is crucial. Our proposed models have significantly improved the accuracy by applying the appropriate flow assumption. However, many opportunities exist to increase the design flexibility and the accuracy. Fluid conditions, such as coolant material and varying volumetric flow rate, can also be part of the optimization parameters to expand the design scope. Moreover, physical phenomena, such as reduced friction on the channel walls or a vortex created on abrupt angle changes, can be considered to improve the accuracy in the closed-form models

System-Level Thermal-Aware Design of 3D Multiprocessors with Inter-Tier Liquid Cooling

Rising chip temperatures and aggravated thermal reliability issues have characterized the emergence of 3D multiprocessor system-on-chips (3D-MPSoCs), necessitating the development of advanced cooling technologies. Microchannel based inter-tier liquid cooling of ICs has been envisaged as the most promising solution to this problem. A system-level thermal-aware design of electronic systems becomes imperative with the advent of these new cooling technologies, in order to preserve the reliable functioning of these ICs and effective management of the rising energy budgets of high-performance computing systems. This paper reviews the recent advances in the area of systemlevel thermal modeling and management techniques for 3D multiprocessors with advanced liquid cooling. These concepts are combined to present a vision of a green data center of the future which reduces the CO2 emissions by reusing the heat it generates