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

Pseudo-functional testing: bridging the gap between manufacturing test and functional operation.

Yuan, Feng.Thesis (M.Phil.)--Chinese University of Hong Kong, 2009.Includes bibliographical references (leaves 60-65).Abstract also in Chinese.Abstract --- p.iAcknowledgement --- p.iiChapter 1 --- Introduction --- p.1Chapter 1.1 --- Manufacturing Test --- p.1Chapter 1.1.1 --- Functional Testing vs. Structural Testing --- p.2Chapter 1.1.2 --- Fault Model --- p.3Chapter 1.1.3 --- Automatic Test Pattern Generation --- p.4Chapter 1.1.4 --- Design for Testability --- p.6Chapter 1.2 --- Pseudo-Functional Manufacturing Test --- p.13Chapter 1.3 --- Thesis Motivation and Organization --- p.16Chapter 2 --- On Systematic Illegal State Identification --- p.19Chapter 2.1 --- Introduction --- p.19Chapter 2.2 --- Preliminaries and Motivation --- p.20Chapter 2.3 --- What is the Root Cause of Illegal States? --- p.22Chapter 2.4 --- Illegal State Identification Flow --- p.26Chapter 2.5 --- Justification Scheme Construction --- p.30Chapter 2.6 --- Experimental Results --- p.34Chapter 2.7 --- Conclusion --- p.35Chapter 3 --- Compression-Aware Pseudo-Functional Testing --- p.36Chapter 3.1 --- Introduction --- p.36Chapter 3.2 --- Motivation --- p.38Chapter 3.3 --- Proposed Methodology --- p.40Chapter 3.4 --- Pattern Generation in Compression-Aware Pseudo-Functional Testing --- p.42Chapter 3.4.1 --- Circuit Pre-Processing --- p.42Chapter 3.4.2 --- Pseudo-Functional Random Pattern Generation with Multi-Launch Cycles --- p.43Chapter 3.4.3 --- Compressible Test Pattern Generation for Pseudo-Functional Testing --- p.45Chapter 3.5 --- Experimental Results --- p.52Chapter 3.5.1 --- Experimental Setup --- p.52Chapter 3.5.2 --- Results and Discussion --- p.54Chapter 3.6 --- Conclusion --- p.56Chapter 4 --- Conclusion and Future Work --- p.58Bibliography --- p.6

Artificial neural network model for arrival time computation in gate level circuits

Advances in the VLSI process technology lead to variations in the process parameters. These process variations severely affect the delay computation of a digital circuit. Under such variations, the various delays, i.e. net delay, gate delay, etc., are no longer deterministic. They are random in nature and are assumed to be probabilistic. They keep changing, based on factors such as process, voltage, temperature, and a few others. This calls for efficient tools to perform timing checks on a design. This work presents a technique to compute the arrival time of a digital circuit. The arrival time (AT) is computed using two different timing engines, namely, static timing analysis (STA) and statistical static timing analysis (SSTA). This work also aims to eliminate number of false paths. It uses a fast and efficient filtering method by utilizing ATPG stuck-at faults and path delay faults. ISCAS-89 benchmark circuits are used for implementation. The results obtained using the probabilistic approach are more accurate than the conventional STA. It has been verified with an Artificial Neural Network (ANN) model. The arrival time calculated using SSTA shows 7% improvement over that of STA. The absolute error is reduced twofold in the case of the ANN model for SSTA

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

Hardware Trojan Detection Using Controlled Circuit Aging

This paper reports a novel approach that uses transistor aging in an integrated circuit (IC) to detect hardware Trojans. When a transistor is aged, it results in delays along several paths of the IC. This increase in delay results in timing violations that reveal as timing errors at the output of the IC during its operation. We present experiments using aging-aware standard cell libraries to illustrate the usefulness of the technique in detecting hardware Trojans. Combining IC aging with over-clocking produces a pattern of bit errors at the IC output by the induced timing violations. We use machine learning to learn the bit error distribution at the output of a clean IC. We differentiate the divergence in the pattern of bit errors because of a Trojan in the IC from this baseline distribution. We simulate the golden IC and show robustness to IC-to-IC manufacturing variations. The approach is effective and can detect a Trojan even if we place it far off the critical paths. Results on benchmarks from the Trust-hub show a detection accuracy of $\geq$99%.Comment: 21 pages, 34 figure

Test and Testability of Asynchronous Circuits

The ever-increasing transistor shrinkage and higher clock frequencies are causing serious clock distribution, power management, and reliability issues. Asynchronous design is predicted to have a significant role in tackling these challenges because of its distributed control mechanism and on-demand, rather than continuous, switching activity. Null Convention Logic (NCL) is a robust and low-power asynchronous paradigm that introduces new challenges to test and testability algorithms because 1) the lack of deterministic timing in NCL complicates the management of test timing, 2) all NCL gates are state-holding and even simple combinational circuits show sequential behaviour, and 3) stuck-at faults on gate internal feedback (GIF) of NCL gates do not always cause an incorrect output and therefore are undetectable by automatic test pattern generation (ATPG) algorithms. Existing test methods for NCL use clocked hardware to control the timing of test. Such test hardware could introduce metastability issues into otherwise highly robust NCL devices. Also, existing test techniques for NCL handle the high-statefulness of NCL circuits by excessive incorporation of test hardware which imposes additional area, propagation delay and power consumption. This work, first, proposes a clockless self-timed ATPG that detects all faults on the gate inputs and a share of the GIF faults with no added design for test (DFT). Then, the efficacy of quiescent current (IDDQ) test for detecting GIF faults undetectable by a DFT-less ATPG is investigated. Finally, asynchronous test hardware, including test points, a scan cell, and an interleaved scan architecture, is proposed for NCL-based circuits. To the extent of our knowledge, this is the first work that develops clockless, self-timed test techniques for NCL while minimising the need for DFT, and also the first work conducted on IDDQ test of NCL. The proposed methods are applied to multiple NCL circuits with up to 2,633 NCL gates (10,000 CMOS Boolean gates), in 180 and 45 nm technologies and show average fault coverage of 88.98% for ATPG alone, 98.52% including IDDQ test, and 99.28% when incorporating test hardware. Given that this fault coverage includes detection of GIF faults, our work has 13% higher fault coverage than previous work. Also, because our proposed clockless test hardware eliminates the need for double-latching, it reduces the average area and delay overhead of previous studies by 32% and 50%, respectively

On Guaranteeing Capture Safety in At-Speed Scan Testing with Broadcast-Scan-Based Test Compression

Capture safety has become a major concern in at-speed scan testing since strong power supply noise caused by excessive launch switching activity (LSA) at transition launching in an at-speed test cycle often results in severe timing-failure-induced yield loss. Recently, a basic RM (rescue-&-mask) test generation scheme was proposed for guaranteeing capture safety rather than merely reducing LSA to some extent. This paper extends the basic RM scheme to broadcast-scan-based test compression by uniquely solving two test-compression-induced problems, namely (1) input X-bit insufficiency (i.e., fewer input X-bits are available for LSA reduction due to test compression) and (2) output X-bit impact (i.e., output X-bits may reduce fault coverage due to test response compaction). This leads to the broadcast-RM (broadcast-scan-based rescue-&-mask) test generation scheme. Evaluations on large benchmark circuits and an industrial circuit of about 1M gates clearly demonstrate that this novel scheme can indeed guarantee capture safety in at-speed scan testing with broadcast-scan-based test compression while minimizing its impact on both test quality and test costs.2013 26th International Conference on VLSI Design, 5-10 January 2013, Pune, Indi

Use It or Lose It: Proactive, Deterministic Longevity in Future Chip Multiprocessors

Ever since the VLSI process technology crossed the sub-micron threshold, there is an increased interest in design of fault-tolerant systems to mitigate the wearout of transistors. Hot Carrier Injection (HCI) and Negative Bias Temperature Instability (NBTI) are two prominent usage based transistor degradation mechanisms in the deep sub-micron process technologies. This wearout of transistors can lead to timing violations along the critical paths which will eventually lead to permanent failures of the chip. While there have been many studies which concentrate on decreasing the wearout in a single core, the failure of an individual core need not be catastrophic in the context of Chip Multi-Processors (CMPs). However, a failure in the interconnect in these CMPs can lead to the failure of entire chip as it could lead to protocol-level deadlocks, or even partition away vital components such as the memory controller or other critical I/O. Analysis of HCI and NBTI stresses caused by real workloads on interconnect microachitecture shows that wearout in the CMP on-chip interconnect is correlated with lack of load observed in the network-on-chip routers. It is proven that exercising the wearout-sensitive components of routers under low load with random inputs can decelerate the NBTI wearout. In this work, we propose a novel deterministic approach for the generation of appropriate exercise mode data to maximize the life-time improvement, ensuring design parameter targets are met. The results from this new proposed design yields ~2300x decrease in the rate of CMP wear due to NBTI compared to that of ~28x decrease shown by previous work