Towards an embedded board-level tester: study of a configurable test processor

The demand for electronic systems with more features, higher performance, and less power consumption increases continuously. This is a real challenge for design and test engineers because they have to deal with electronic systems with ever-increasing complexity maintaining production and test costs low and meeting critical time to market deadlines. For a test engineer working at the board-level, this means that manufacturing defects must be detected as soon as possible and at a low cost. However, the use of classical test techniques for testing modern printed circuit boards is not sufficient, and in the worst case these techniques cannot be used at all. This is mainly due to modern packaging technologies, a high device density, and high operation frequencies of modern printed circuit boards. This leads to very long test times, low fault coverage, and high test costs. This dissertation addresses these issues and proposes an FPGA-based test approach for printed circuit boards. The concept is based on a configurable test processor that is temporarily implemented in the on-board FPGA and provides the corresponding mechanisms to communicate to external test equipment and co-processors implemented in the FPGA. This embedded test approach provides the flexibility to implement test functions either in the external test equipment or in the FPGA. In this manner, tests are executed at-speed increasing the fault coverage, test times are reduced, and the test system can be adapted automatically to the properties of the FPGA and devices located on the board. An essential part of the FPGA-based test approach deals with the development of a test processor. In this dissertation the required properties of the processor are discussed, and it is shown that the adaptation to the specific test scenario plays a very important role for the optimization. For this purpose, the test processor is equipped with configuration parameters at the instruction set architecture and microarchitecture level. Additionally, an automatic generation process for the test system and for the computation of some of the processor’s configuration parameters is proposed. The automatic generation process uses as input a model known as the device under test model (DUT-M). In order to evaluate the entire FPGA-based test approach and the viability of a processor for testing printed circuit boards, the developed test system is used to test interconnections to two different devices: a static random memory (SRAM) and a liquid crystal display (LCD). Experiments were conducted in order to determine the resource utilization of the processor and FPGA-based test system and to measure test time when different test functions are implemented in the external test equipment or the FPGA. It has been shown that the introduced approach is suitable to test printed circuit boards and that the test processor represents a realistic alternative for testing at board-level.Der Bedarf an elektronischen Systemen mit zusätzlichen Merkmalen, höherer Leistung und geringerem Energieverbrauch nimmt ständig zu. Dies stellt eine erhebliche Herausforderung für Entwicklungs- und Testingenieure dar, weil sie sich mit elektronischen Systemen mit einer steigenden Komplexität zu befassen haben. Außerdem müssen die Herstellungs- und Testkosten gering bleiben und die Produkteinführungsfristen so kurz wie möglich gehalten werden. Daraus folgt, dass ein Testingenieur, der auf Leiterplatten-Ebene arbeitet, die Herstellungsfehler so früh wie möglich entdecken und dabei möglichst niedrige Kosten verursachen soll. Allerdings sind die klassischen Testmethoden nicht in der Lage, die Anforderungen von modernen Leiterplatten zu erfüllen und im schlimmsten Fall können diese Testmethoden überhaupt nicht verwendet werden. Dies liegt vor allem an modernen Gehäuse-Technologien, der hohen Bauteildichte und den hohen Arbeitsfrequenzen von modernen Leiterplatten. Das führt zu sehr langen Testzeiten, geringer Testabdeckung und hohen Testkosten. Die Dissertation greift diese Problematik auf und liefert einen FPGA-basierten Testansatz für Leiterplatten. Das Konzept beruht auf einem konfigurierbaren Testprozessor, welcher im On-Board-FPGA temporär implementiert wird und die entsprechenden Mechanismen für die Kommunikation mit der externen Testeinrichtung und Co-Prozessoren im FPGA bereitstellt. Dadurch ist es möglich Testfunktionen flexibel entweder auf der externen Testeinrichtung oder auf dem FPGA zu implementieren. Auf diese Weise werden Tests at-speed ausgeführt, um die Testabdeckung zu erhöhen. Außerdem wird die Testzeit verkürzt und das Testsystem automatisch an die Eigenschaften des FPGAs und anderer Bauteile auf der Leiterplatte angepasst. Ein wesentlicher Teil des FPGA-basierten Testansatzes umfasst die Entwicklung eines Testprozessors. In dieser Dissertation wird über die benötigten Eigenschaften des Prozessors diskutiert und es wird gezeigt, dass die Anpassung des Prozessors an den spezifischen Testfall von großer Bedeutung für die Optimierung ist. Zu diesem Zweck wird der Prozessor mit Konfigurationsparametern auf der Befehlssatzarchitektur-Ebene und Mikroarchitektur-Ebene ausgerüstet. Außerdem wird ein automatischer Generierungsprozess für die Realisierung des Testsystems und für die Berechnung einer Untergruppe von Konfigurationsparametern des Prozessors vorgestellt. Der automatische Generierungsprozess benutzt als Eingangsinformation ein Modell des Prüflings (device under test model, DUT-M). Das entwickelte Testsystem wurde zum Testen von Leiterplatten für Verbindungen zwischen dem FPGA und zwei Bauteilen verwendet, um den FPGA-basierten Testansatz und die Durchführbarkeit des Testprozessors für das Testen auf Leiterplatte-Ebene zu evaluieren. Die zwei Bauteile sind ein Speicher mit direktem Zugriff (static random-access memory, SRAM) und eine Flüssigkristallanzeige (liquid crystal display, LCD). Die Experimente wurden durchgeführt, um den Ressourcenverbrauch des Prozessors und Testsystems festzustellen und um die Testzeit zu messen. Dies geschah durch die Implementierung von unterschiedlichen Testfunktionen auf der externen Testeinrichtung und dem FPGA. Dadurch konnte gezeigt werden, dass der FPGA-basierte Ansatz für das Testen von Leiterplatten geeignet ist und dass der Testprozessor eine realistische Alternative für das Testen auf Leiterplatten-Ebene ist

Design and Validation of Network-on-Chip Architectures for the Next Generation of Multi-synchronous, Reliable, and Reconfigurable Embedded Systems

NETWORK-ON-CHIP (NoC) design is today at a crossroad. On one hand, the design principles to efficiently implement interconnection networks in the resource-constrained on-chip setting have stabilized. On the other hand, the requirements on embedded system design are far from stabilizing. Embedded systems are composed by assembling together heterogeneous components featuring differentiated operating speeds and ad-hoc counter measures must be adopted to bridge frequency domains. Moreover, an unmistakable trend toward enhanced reconfigurability is clearly underway due to the increasing complexity of applications. At the same time, the technology effect is manyfold since it provides unprecedented levels of system integration but it also brings new severe constraints to the forefront: power budget restrictions, overheating concerns, circuit delay and power variability, permanent fault, increased probability of transient faults. Supporting different degrees of reconfigurability and flexibility in the parallel hardware platform cannot be however achieved with the incremental evolution of current design techniques, but requires a disruptive approach and a major increase in complexity. In addition, new reliability challenges cannot be solved by using traditional fault tolerance techniques alone but the reliability approach must be also part of the overall reconfiguration methodology. In this thesis we take on the challenge of engineering a NoC architectures for the next generation systems and we provide design methods able to overcome the conventional way of implementing multi-synchronous, reliable and reconfigurable NoC. Our analysis is not only limited to research novel approaches to the specific challenges of the NoC architecture but we also co-design the solutions in a single integrated framework. Interdependencies between different NoC features are detected ahead of time and we finally avoid the engineering of highly optimized solutions to specific problems that however coexist inefficiently together in the final NoC architecture. To conclude, a silicon implementation by means of a testchip tape-out and a prototype on a FPGA board validate the feasibility and effectivenes

High Quality Test Generation Targeting Power Supply Noise

Delay test is an essential structural manufacturing test used to determine the maximal frequency at which a chip can run without incurring any functional failures. The central unsolved challenge is achieving high delay correlation with the functional test, which is dominated by power supply noise (PSN). Differences in PSN between functional and structural tests can lead to differences in chip operating frequencies of 30% or more. Pseudo functional test (PFT), based on a multiple-cycle clocking scheme, has better PSN correlation with functional test compared with traditional two-cycle at-speed test. However, PFT is vulnerable to under-testing when applied to delay test. This work aims to generate high quality PFT patterns, achieving high PSN correlation with functional test. First, a simulation-based don’t-care filling algorithm, Bit-Flip, is proposed to improve the PSN for PFT. It relies on randomly flipping a group of bits in the test pattern to explore the search space and find patterns that stress the circuits with the worst-case, but close to functional PSN. Experimental results on un-compacted patterns show Bit-Flip is able to improve PSN as much as 38.7% compared with the best random fill. Second, techniques are developed to improve the efficiency of Bit-Flip. A set of partial patterns, which sensitize transitions on critical cells, are pre-computed and later used to guide the selection of bits to flip. Combining random and deterministic flipping, we achieve similar PSN control as Bit-Flip but with much less simulation time. Third, we address the problem of automatic test pattern generation for extracting circuit timing sensitivity to power supply noise during post-silicon validation. A layout-aware path selection algorithm selects long paths to fully span the power delivery network. The selected patterns are intelligently filled to bring the PSN to a desired level. These patterns can be used to understand timing sensitivity in post-silicon validation by repeatedly applying the path delay test while sweeping the PSN experienced by the path from low to high. Finally, the impacts of compression on power supply noise control are studied. Illinois Scan and embedded deterministic test (EDT) patterns are generated. Then Bit-Flip is extended to incorporate the compression constraints and applied to compressible patterns. The experimental results show that EDT lowers the maximal PSN by 24.15% and Illinois Scan lowers it by 2.77% on un-compacted patterns

Design, Analysis and Test of Logic Circuits under Uncertainty.

Integrated circuits are increasingly susceptible to uncertainty caused by soft errors, inherently probabilistic devices, and manufacturing variability. As device technologies scale, these effects become detrimental to circuit reliability. In order to address this, we develop methods for analyzing, designing, and testing circuits subject to probabilistic effects. Our main contributions are: 1) a fast, soft-error rate (SER) analyzer that uses functional-simulation signatures to capture error effects, 2) novel design techniques that improve reliability using little area and performance overhead, 3) a matrix-based reliability-analysis framework that captures many types of probabilistic faults, and 4) test-generation/compaction methods aimed at probabilistic faults in logic circuits. SER analysis must account for the main error-masking mechanisms in ICs: logic, timing, and electrical masking. We relate logic masking to node testability of the circuit and utilize functional-simulation signatures, i.e., partial truth tables, to efficiently compute estability (signal probability and observability). To account for timing masking, we compute error-latching windows (ELWs) from timing analysis information. Electrical masking is incorporated into our estimates through derating factors for gate error probabilities. The SER of a circuit is computed by combining the effects of all three masking mechanisms within our SER analyzer called AnSER. Using AnSER, we develop several low-overhead techniques that increase reliability, including: 1) an SER-aware design method that uses redundancy already present within the circuit, 2) a technique that resynthesizes small logic windows to improve area and reliability, and 3) a post-placement gate-relocation technique that increases timing masking by decreasing ELWs. We develop the probabilistic transfer matrix (PTM) modeling framework to analyze effects beyond soft errors. PTMs are compressed into algebraic decision diagrams (ADDs) to improve computational efficiency. Several ADD algorithms are developed to extract reliability and error susceptibility information from PTMs representing circuits. We propose new algorithms for circuit testing under probabilistic faults, which require a reformulation of existing test techniques. For instance, a test vector may need to be repeated many times to detect a fault. Also, different vectors detect the same fault with different probabilities. We develop test generation methods that account for these differences, and integer linear programming (ILP) formulations to optimize test sets.Ph.D.Computer Science & EngineeringUniversity of Michigan, Horace H. Rackham School of Graduate Studieshttp://deepblue.lib.umich.edu/bitstream/2027.42/61584/1/smita_1.pd

Modellierung und automatische Generierung von FPGA-basierten Testinstrumenten für den strukturellen Leiterplattentest

Neue Bauformen von Schaltkreisen wie BGAs führen zu sinkenden Möglichkeiten des optischen und mechanischen Testzugriffs und stellen Testsysteme vor Probleme bei der Testbarkeit von Verbindungen zwischen ICs auf Leiterplatten. Damit verbunden sind eine reduzierte Testabdeckung und steigende Kosten. Besonders für FPGAs fehlen geeignete Methoden, bei denen sich das Testsystem automatisch den Gegebenheiten der zu testenden Leiterplatte anpasst. Diese Dissertation beschäftigt sich mit dem Problem des FPGA-basierten Testens. Das vorgestellte Konzept nutzt ausschließlich vorhandene Ressourcen des FPGAs, um Testalgorithmen in dessen Logik zu implementieren und erhöht die Herstellungskosten der Leiterplatte nicht. Die Ressourcen des FPGAs stehen während der Testphase exklusiv für das Testen zur Verfügung. Ausgehend vom Stand der Technik nicht-invasiver elektrischer Verfahren für Leiterplattentests werden aktuelle Ansätze und Methoden miteinander verglichen. Aus deren Stärken und Schwächen wird eine detaillierte Zielstellung für diese Dissertation erarbeitet. Es wird eine Methode zur Generierung von Testinstrumenten für das FPGA-basierte Testen vorgestellt, die die Ausführung von Testalgorithmen in den FPGA verlagern und eine vergleichbare oder bessere Testabdeckung sowie Testgeschwindigkeit als etablierte Verfahren liefert, ohne dafür auf manuelle Eingriffe bei der Generierung angewiesen zu sein. Im Rahmen eines Lösungsansatzes wird neben der Testsystemarchitektur eine Modellierung für die an den Verbindungstests beteiligten Schaltkreise vorgestellt. Hierbei wird die Ausführung der Testalgorithmen im FPGA entweder in Software auf einem softcore-basierten Prozessor oder direkt in Hardware als diskrete Logik in einem sogenannten Co-Prozessor ermöglicht. Mit der Methode ist es möglich jeden Schaltkreis getrennt und unabhängig von der Art seiner späteren Implementierung und den konkreten Gegebenheiten des Prüflings zu modellieren. Die Generierung aller nötigen Bestandteile in Software und Hardware, wie auch deren Integration zu einem Testinstrument erfolgen dabei vollständig automatisch. Kern der Arbeit ist die Modellierung und Generierung für eingebettete Testinstrumente, die auf der Testsystemarchitektur basieren. Der Fokus wird dabei auf die zeitlich korrekte Ansteuerung der an den Verbindungstests beteiligten Schaltkreise gelegt, ohne dabei eine konkrete Implementierung vorzugeben. In Untersuchungen wird die Generierung von Testinstrumenten für verschiedene Schaltkreise betrachtet. Die Ergebnisse belegen die Leistungsfähigkeit der vorgestellten Methode zur automatischen Generierung von FPGA-basierten Testinstrumenten und zeigen eine signifikante Beschleunigung des FPGA-basierten Verbindungstests.New types of cases for integrated circuits like BGAs are leading to a decreased optical and mechanical test access. They are causing problems for test systems when testing connections between integrated circuits on printed circuit boards. This causes decreasing test coverage and increasing test costs. Especially for FPGAs some appropriate methods that automatically adapt the test system to the conditions of the printed circuit board are missing. This thesis is about the problems of FPGA-based testing. The presented concept solely uses available resources of the FPGA to transfer test algorithms from external test equipment into the programmable logic of the FPGA and therefore does not increase the production costs of the printed circuit board. The resources of the FPGA are exclusively used for testing during the test phase. Based on state-of-the-art non-invasive electrical methods for printed circuit boards with FPGAs current approaches are compared and analyzed. From the strengths and weaknesses of the considered methods a detailed description of the goals that should be achieved with this thesis is discussed. A method for the generation of so called test instruments for FPGA-based testing is presented. This method transfers the execution of test algorithms into the FPGA and has a similar or better test coverage as well as test speed compared to the well-established techniques without the need for any manually actions when generating such systems. Besides the chosen test system architecture the modeling of integrated circuits that are part of the connection test is presented. The test system architecture allows the execution of test algorithms either in software on a soft-core processor or directly in dedicated logic, so called co-processors. With this method it is possible to model each integrated circuit independent of each other and also independent of the implementation in software or hardware. The generation of all software and hardware parts of the test system is done fully automatically. Central element of this thesis is the modeling and generation of embedded test instruments, based on the presented test system architecture. The focus is on the timing-correct control routines of the integrated circuits that are part of the connection test. All parts of the test system should be modeled independent of each other and without knowledge about the use case. In experiments the generation of test instruments for different integrated circuits is carried out. These experiments prove the performance of the proposed methods for automatic generation of FPGA-based test instrument and show a significant speed-up for FPGA-based tests of printed circuit boards

Tiled microprocessors

Thesis (Ph. D.)--Massachusetts Institute of Technology, Dept. of Electrical Engineering and Computer Science, 2007.Includes bibliographical references (p. 251-258).Current-day microprocessors have reached the point of diminishing returns due to inherent scalability limitations. This thesis examines the tiled microprocessor, a class of microprocessor which is physically scalable but inherits many of the desirable properties of conventional microprocessors. Tiled microprocessors are composed of an array of replicated tiles connected by a special class of network, the Scalar Operand Network (SON), which is optimized for low-latency, low-occupancy communication between remote ALUs on different tiles. Tiled microprocessors can be constructed to scale to 100's or 1000's of functional units. This thesis identifies seven key criteria for achieving physical scalability in tiled microprocessors. It employs an archetypal tiled microprocessor to examine the challenges in achieving these criteria and to explore the properties of Scalar Operand Networks. The thesis develops the field of SONs in three major ways: it introduces the 5-tuple performance metric, it describes a complete, high-frequency SON implementation, and it proposes a taxonomy, called AsTrO, for categorizing them.(cont.) To develop these ideas, the thesis details the design, implementation and analysis of a tiled microprocessor prototype, the Raw Microprocessor, which was implemented at MIT in 180 nm technology. Overall, compared to Raw, recent commercial processors with half the transistors required 30x as many lines of code, occupied 100x as many designers, contained 50x as many pre-tapeout bugs, and resulted in 33x as many post-tapeout bugs. At the same time, the Raw microprocessor proves to be more versatile in exploiting ILP, stream, and server-farm workloads with modest to large amounts of parallelism.by Michael Bedford Taylor.Ph.D