Fault Detection Methodology for Caches in Reliable Modern VLSI Microprocessors based on Instruction Set Architectures

Η παρούσα διδακτορική διατριβή εισάγει μία χαμηλού κόστους μεθοδολογία για την ανίχνευση ελαττωμάτων σε μικρές ενσωματωμένες κρυφές μνήμες που βασίζεται σε σύγχρονες Αρχιτεκτονικές Συνόλου Εντολών και εφαρμόζεται με λογισμικό αυτοδοκιμής. Η προτεινόμενη μεθοδολογία εφαρμόζει αλγορίθμους March μέσω λογισμικού για την ανίχνευση τόσο ελαττωμάτων αποθήκευσης όταν εφαρμόζεται σε κρυφές μνήμες που περιέχουν μόνο στατικές μνήμες τυχαίας προσπέλασης όπως για παράδειγμα κρυφές μνήμες επιπέδου 1, όσο και ελαττωμάτων σύγκρισης όταν εφαρμόζεται σε κρυφές μνήμες που περιέχουν εκτός από SRAM μνήμες και μνήμες διευθυνσιοδοτούμενες μέσω περιεχομένου, όπως για παράδειγμα πλήρως συσχετιστικές κρυφές μνήμες αναζήτησης μετάφρασης. Η προτεινόμενη μεθοδολογία εφαρμόζεται και στις τρεις οργανώσεις συσχετιστικότητας κρυφής μνήμης και είναι ανεξάρτητη της πολιτικής εγγραφής στο επόμενο επίπεδο της ιεραρχίας. Η μεθοδολογία αξιοποιεί υπάρχοντες ισχυρούς μηχανισμούς των μοντέρνων ISAs χρησιμοποιώντας ειδικές εντολές, που ονομάζονται στην παρούσα διατριβή Εντολές Άμεσης Προσπέλασης Κρυφής Μνήμης (Direct Cache Access Instructions - DCAs). Επιπλέον, η προτεινόμενη μεθοδολογία εκμεταλλεύεται τους έμφυτους μηχανισμούς καταγραφής απόδοσης και τους μηχανισμούς χειρισμού παγίδων που είναι διαθέσιμοι στους σύγχρονους επεξεργαστές. Επιπρόσθετα, η προτεινόμενη μεθοδολογία εφαρμόζει την λειτουργία σύγκρισης των αλγορίθμων March όταν αυτή απαιτείται (για μνήμες CAM) και επαληθεύει το αποτέλεσμα του ελέγχου μέσω σύντομης απόκρισης, ώστε να είναι συμβατή με τις απαιτήσεις του ελέγχου εντός λειτουργίας. Τέλος, στη διατριβή προτείνεται μία βελτιστοποίηση της μεθοδολογίας για πολυνηματικές, πολυπύρηνες αρχιτεκτονικές.The present PhD thesis introduces a low cost fault detection methodology for small embedded cache memories that is based on modern Instruction Set Architectures and is applied with Software-Based Self-Test (SBST) routines. The proposed methodology applies March tests through software to detect both storage faults when applied to caches that comprise Static Random Access Memories (SRAM) only, e.g. L1 caches, and comparison faults when applied to caches that apart from SRAM memories comprise Content Addressable Memories (CAM) too, e.g. Translation Lookaside Buffers (TLBs). The proposed methodology can be applied to all three cache associativity organizations: direct mapped, set-associative and full-associative and it does not depend on the cache write policy. The methodology leverages existing powerful mechanisms of modern ISAs by utilizing instructions that we call in this PhD thesis Direct Cache Access (DCA) instructions. Moreover, our methodology exploits the native performance monitoring hardware and the trap handling mechanisms which are available in modern microprocessors. Moreover, the proposed Methodology applies March compare operations when needed (for CAM arrays) and verifies the test result with a compact response to comply with periodic on-line testing needs. Finally, a multithreaded optimization of the proposed methodology that targets multithreaded, multicore architectures is also presented in this thesi

New techniques for functional testing of microprocessor based systems

Electronic devices may be affected by failures, for example due to physical defects. These defects may be introduced during the manufacturing process, as well as during the normal operating life of the device due to aging. How to detect all these defects is not a trivial task, especially in complex systems such as processor cores. Nevertheless, safety-critical applications do not tolerate failures, this is the reason why testing such devices is needed so to guarantee a correct behavior at any time. Moreover, testing is a key parameter for assessing the quality of a manufactured product. Consolidated testing techniques are based on special Design for Testability (DfT) features added in the original design to facilitate test effectiveness. Design, integration, and usage of the available DfT for testing purposes are fully supported by commercial EDA tools, hence approaches based on DfT are the standard solutions adopted by silicon vendors for testing their devices. Tests exploiting the available DfT such as scan-chains manipulate the internal state of the system, differently to the normal functional mode, passing through unreachable configurations. Alternative solutions that do not violate such functional mode are defined as functional tests. In microprocessor based systems, functional testing techniques include software-based self-test (SBST), i.e., a piece of software (referred to as test program) which is uploaded in the system available memory and executed, with the purpose of exciting a specific part of the system and observing the effects of possible defects affecting it. SBST has been widely-studies by the research community for years, but its adoption by the industry is quite recent. My research activities have been mainly focused on the industrial perspective of SBST. The problem of providing an effective development flow and guidelines for integrating SBST in the available operating systems have been tackled and results have been provided on microprocessor based systems for the automotive domain. Remarkably, new algorithms have been also introduced with respect to state-of-the-art approaches, which can be systematically implemented to enrich SBST suites of test programs for modern microprocessor based systems. The proposed development flow and algorithms are being currently employed in real electronic control units for automotive products. Moreover, a special hardware infrastructure purposely embedded in modern devices for interconnecting the numerous on-board instruments has been interest of my research as well. This solution is known as reconfigurable scan networks (RSNs) and its practical adoption is growing fast as new standards have been created. Test and diagnosis methodologies have been proposed targeting specific RSN features, aimed at checking whether the reconfigurability of such networks has not been corrupted by defects and, in this case, at identifying the defective elements of the network. The contribution of my work in this field has also been included in the first suite of public-domain benchmark networks

Exploring the Mysteries of System-Level Test

System-level test, or SLT, is an increasingly important process step in today's integrated circuit testing flows. Broadly speaking, SLT aims at executing functional workloads in operational modes. In this paper, we consolidate available knowledge about what SLT is precisely and why it is used despite its considerable costs and complexities. We discuss the types or failures covered by SLT, and outline approaches to quality assessment, test generation and root-cause diagnosis in the context of SLT. Observing that the theoretical understanding for all these questions has not yet reached the level of maturity of the more conventional structural and functional test methods, we outline new and promising directions for methodical developments leveraging on recent findings from software engineering.Comment: 7 pages, 2 figure

Innovative Techniques for Testing and Diagnosing SoCs

We rely upon the continued functioning of many electronic devices for our everyday welfare, usually embedding integrated circuits that are becoming even cheaper and smaller with improved features. Nowadays, microelectronics can integrate a working computer with CPU, memories, and even GPUs on a single die, namely System-On-Chip (SoC). SoCs are also employed on automotive safety-critical applications, but need to be tested thoroughly to comply with reliability standards, in particular the ISO26262 functional safety for road vehicles. The goal of this PhD. thesis is to improve SoC reliability by proposing innovative techniques for testing and diagnosing its internal modules: CPUs, memories, peripherals, and GPUs. The proposed approaches in the sequence appearing in this thesis are described as follows: 1. Embedded Memory Diagnosis: Memories are dense and complex circuits which are susceptible to design and manufacturing errors. Hence, it is important to understand the fault occurrence in the memory array. In practice, the logical and physical array representation differs due to an optimized design which adds enhancements to the device, namely scrambling. This part proposes an accurate memory diagnosis by showing the efforts of a software tool able to analyze test results, unscramble the memory array, map failing syndromes to cell locations, elaborate cumulative analysis, and elaborate a final fault model hypothesis. Several SRAM memory failing syndromes were analyzed as case studies gathered on an industrial automotive 32-bit SoC developed by STMicroelectronics. The tool displayed defects virtually, and results were confirmed by real photos taken from a microscope. 2. Functional Test Pattern Generation: The key for a successful test is the pattern applied to the device. They can be structural or functional; the former usually benefits from embedded test modules targeting manufacturing errors and is only effective before shipping the component to the client. The latter, on the other hand, can be applied during mission minimally impacting on performance but is penalized due to high generation time. However, functional test patterns may benefit for having different goals in functional mission mode. Part III of this PhD thesis proposes three different functional test pattern generation methods for CPU cores embedded in SoCs, targeting different test purposes, described as follows: a. Functional Stress Patterns: Are suitable for optimizing functional stress during I Operational-life Tests and Burn-in Screening for an optimal device reliability characterization b. Functional Power Hungry Patterns: Are suitable for determining functional peak power for strictly limiting the power of structural patterns during manufacturing tests, thus reducing premature device over-kill while delivering high test coverage c. Software-Based Self-Test Patterns: Combines the potentiality of structural patterns with functional ones, allowing its execution periodically during mission. In addition, an external hardware communicating with a devised SBST was proposed. It helps increasing in 3% the fault coverage by testing critical Hardly Functionally Testable Faults not covered by conventional SBST patterns. An automatic functional test pattern generation exploiting an evolutionary algorithm maximizing metrics related to stress, power, and fault coverage was employed in the above-mentioned approaches to quickly generate the desired patterns. The approaches were evaluated on two industrial cases developed by STMicroelectronics; 8051-based and a 32-bit Power Architecture SoCs. Results show that generation time was reduced upto 75% in comparison to older methodologies while increasing significantly the desired metrics. 3. Fault Injection in GPGPU: Fault injection mechanisms in semiconductor devices are suitable for generating structural patterns, testing and activating mitigation techniques, and validating robust hardware and software applications. GPGPUs are known for fast parallel computation used in high performance computing and advanced driver assistance where reliability is the key point. Moreover, GPGPU manufacturers do not provide design description code due to content secrecy. Therefore, commercial fault injectors using the GPGPU model is unfeasible, making radiation tests the only resource available, but are costly. In the last part of this thesis, we propose a software implemented fault injector able to inject bit-flip in memory elements of a real GPGPU. It exploits a software debugger tool and combines the C-CUDA grammar to wisely determine fault spots and apply bit-flip operations in program variables. The goal is to validate robust parallel algorithms by studying fault propagation or activating redundancy mechanisms they possibly embed. The effectiveness of the tool was evaluated on two robust applications: redundant parallel matrix multiplication and floating point Fast Fourier Transform

Self-Test Mechanisms for Automotive Multi-Processor System-on-Chips

L'abstract è presente nell'allegato / the abstract is in the attachmen

A Decentralized Scheduler for On-line Self-test Routines in Multi-core Automotive System-on-Chips

Modern System-on-Chips (SoCs) deployed for safety-critical applications typically embed one or more processing cores along with a variable number of peripherals. The compliance of such designs with functional safety standards is achieved by a combination of different techniques based on hardware redundancy and in-field test mechanisms. Among these, Software Test Libraries (STLs) are rapidly becoming adopted for testing the CPU and peripherals modules. The STL is usually composed of two sets of self-test procedures: boot-time and run-time tests. The former set is typically executed during the boot or power-on phase of the SoC since it requires full access to the available hardware (e.g., these programs need to manipulate the Interrupt Vector Table and to access the system RAM). The latter set instead, is designed to coexist with the user application and can be executed without requiring special constraints. When the STL is intended for testing the different cores within a multi-core SoC, the concurrent execution of the boot-time self-tests becomes an issue since this could lead to a longer power-up phase and excessive utilization of system resources. The main intent of this work is to present the architecture of a decentralized software scheduler, conceived for the concurrent execution of the STL on the available cores. The proposed solution considers the typical constraints of an STL in a multi-core scenario when deployed in field, namely minimum system resources usage (i.e., code and data memory). The effectiveness of the proposed scheduler was experimentally evaluated on an industrial STL developed for a multi-core SoC manufactured by STMicroelectronics

STANDARDIZING FUNCTIONAL SAFETY ASSESSMENTS FOR OFF-THE-SHELF INSTRUMENTATION AND CONTROLS

It is typical for digital instrumentation and controls, used to manage significant risk, to undergo substantial amounts of scrutiny. The equipment must be proven to have the necessary level of design integrity. The details of the scrutiny vary based on the particular industry, but the ultimate goal is to provide sufficient evidence that the equipment will operate successfully when performing their required functions. To be able to stand up to the scrutiny and more importantly, successfully perform the required safety functions, the equipment must be designed to defend against random hardware failures and also to prevent systematic faults. These design activities must also have been documented in a manner that sufficiently proves their adequacy. The variability in the requirements of the different industries makes this task difficult for instrumentation and controls equipment manufacturers. To assist the manufacturers in dealing with these differences, a standardization of requirements is needed to facilitate clear communication of expectations. The IEC 61508 set of standards exists to fulfill this role, but it is not yet universally embraced. After that occurs, various industries, from nuclear power generation to oil & gas production, will benefit from the existence of a wider range of equipment that has been designed to perform in these critical roles and that also includes the evidence necessary to prove its integrity. The manufacturers will then be able to enjoy the benefit of having a larger customer base interested in their products. The use of IEC 61508 will also help industries avoid significant amounts of uncertainty when selecting commercial off-the-shelf equipment. It is currently understood that it cannot be assumed that a typical commercial manufacturer’s equipment designs and associated design activities will be adequate to allow for success in these high risk applications. In contrast, a manufacturer that seeks to comply with IEC 61508 and seeks to achieve certification by an independent third party can be assumed to be better suited for meeting the needs of these demanding situations. Use of these manufacturers help to avoid substantial uncertainty and risk

ASIC Technology Migrations: A Design Guide for First Pass Success

This thesis presents a study of Application Specific Integrated Circuit (ASIC) technology migrations. An overview of the design flow methodology used for completing a ASIC design from concept to silicon is presented. The design flow is then augmented with special considerations specifically for ASIC technology migrations. An ASIC technology migration design example, using the special considerations, is preseted. Finally, a summary is presented with considerations regarding future work

Selection of a new hardware and software platform for railway interlocking

The interlocking system is one of the main actors for safe railway transportation. In most cases, the whole system is supplied by a single vendor. The recent regulations from the European Union direct for an “open” architecture to invite new game changers and reduce life-cycle costs. The objective of the thesis is to propose an alternative platform that could replace a legacy interlocking system. In the thesis, various commercial off-the-shelf hardware and software products are studied which could be assembled to compose an alternative interlocking platform. The platform must be open enough to adapt to any changes in the constituent elements and abide by the proposed baselines of new standardization initiatives, such as ERTMS, EULYNX, and RCA. In this thesis, a comparative study is performed between these products based on hardware capacity, architecture, communication protocols, programming tools, security, railway certifications, life-cycle issues, etc

Advanced Platform Systems Technology study. Volume 2: Trade study and technology selection

Three primary tasks were identified which include task 1-trade studies, task 2-trade study comparison and technology selection, and task 3-technology definition. Task 1 general objectives were to identify candidate technology trade areas, determine which areas have the highest potential payoff, define specific trades within the high payoff areas, and perform the trade studies. In order to satisfy these objectives, a structured, organized approach was employed. Candidate technology areas and specific trades were screened using consistent selection criteria and considering possible interrelationships. A data base comprising both manned and unmanned space platform documentation was used as a source of system and subsystem requirements. When requirements were not stated in the data base documentation, assumptions were made and recorded where necessary to characterize a particular spacecraft system. The requirements and assumptions were used together with the selection criteria to establish technology advancement goals and select trade studies. While both manned and unmanned platform data were used, the study was focused on the concept of an early manned space station