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

Maximizing the Switching Activity of Different Modules Within a Processor Core via Evolutionary Techniques

One key aspect to be considered during device testing is the minimization of the switching activity of the circuit under test (CUT), thus avoiding possible problems stemming from overheating it. But there are also scenarios, where the maximization of certain circuits' modules switching activity could be proven useful (e.g., during Burn-In) in order to exercise the circuit under extreme operating conditions in terms of temperature (and temperature gradients). Resorting to a functional approach based on Software-based Self-test guarantees that the high induced activity cannot damage the CUT nor produce any yield loss. However, the generation of effective suitable test programs remains a challenging task. In this paper, we consider a scenario where the modules to be stressed are sub-modules of a fully pipelined processor. We present a technique, based on an evolutionary approach, able to automatically generate stress test programs, i.e., sequences of instructions achieving a high toggling activity in the target module. With respect to previous approaches, the generated sequences are short and repeatable, thus guaranteeing their easy usability to stress a module (and increase its temperature). The processor we used for our experiments is the Open RISC 1200. Results demonstrate that the proposed method is effective in achieving a high value of sustained toggling activity with short (3 instructions) and repeatable sequences

A Functional Approach to Test and Debug of IEEE 1687 Reconfigurable Networks

The IEEE 1687 standard introduces several novelties, most notably Reconfigurable Scan Networks (RSNs), i.e., scan chains whose length can change dynamically. These architectures offer important advantages but can result in extremely complex integrity test following traditional structural approaches. In this paper, we will present an innovative approach to RSN test and debug based on the functional features of the standard, which is able to greatly speed up test generation time while guaranteeing a precise fault coverage

An Enhanced Evolutionary Technique for the Generation of Compact Reconfigurable Scan-Network Tests

Nowadays many Integrated Systems embed auxiliary on-chip instruments whose function is to perform test, debug, calibration, configuration, etc. The growing complexity and the increasing number of these instruments have led to new solutions for their access and control, such as the IEEE 1687 standard. The standard introduces an infrastructure composed of scan chains incorporating configurable elements for accessing the instruments in a flexible manner. Such an infrastructure is known as Reconfigurable Scan Network or RSN. Since permanent faults affecting the circuitry can cause malfunction, i.e., inappropriate behaviour, detecting them is of utmost importance. This paper addresses the issue of generating effective sequences for testing the reconfigurable elements within RSNs using evolutionary computation. Test configurations are extracted with automatic test pattern generation (ATPG) and used to guide the evolution. Postprocessing techniques are proposed to improve the evolutionary fittest solution. Results on a standard set of benchmark networks show up to 27% reduced test time with respect to test generation based on RSN exploratio

Self-Test Libraries Analysis for Pipelined Processors Transition Fault Coverage Improvement

Testing digital integrated circuits is generally done using Design-for-Testability (DfT) solutions. Such solutions, however, introduce non-negligible area and timing overheads that can be overcome by adopting functional solutions. In particular, functional test of integrated circuits plays a key role when guaranteeing the device's safety is required during the operative lifetime (in-field test), as required by standards like ISO26262. This can be achieved via the execution of a Self-Test Library (STL) by the device under test (DUT). Nevertheless, developing such test programs requires a significant manual effort, and can be non-trivial when dealing with complex modules. This paper moves the first step in defining a generic and systematic methodology to improve transition delay faults' observability of existing STLs. To do so, we analyze previously devised STLs in order to highlight specific points within test programs to be improved, leading to an increase in the final fault coverage

A New Technique to Generate Test Sequences for Reconfigurable Scan Networks

Nowadays, industries require reliable methods for accessing the instrumentations embedded within semiconductor devices. The situation led to the definition of standards, such as the IEEE 1687, for designing the required infrastructures, and the proposal of techniques to test them. So far, most of the test-generation approaches are either too computationally demanding to be applied in complex cases, or too approximate to yield high-quality tests. This paper exploits a recent idea: the state of a generic reconfigurable scan chain is modeled as a finite state automaton and a low-level fault, as an incorrect transition; it then proposes a new algorithm for generating a functional test sequence able to detect all incorrect transitions far more efficiently than previous ones. Such an algorithm is based on a greedy search, and it is able to postpone costly operations and eventually minimize their number. Experimental results on ITC’16 benchmarks demonstrate that the proposed approach is broadly applicable; has limited computational requirements; and the test sequences are order of magnitudes shorter than the ones previously generated by approximate methodologies

A Semi-Formal Technique to Generate Effective Test Sequences for Reconfigurable Scan Networks

The broad need to efficiently access all the instrumentation embedded within a semiconductor device called for a standardization, and the reconfigurable scan networks proposed in IEEE 1687 have been demonstrated effective in handling complex infrastructures. At the same time, different techniques have been proposed to test the new circuitry required; however, most of the automatic approaches are either too computationally demanding to be applied in complex cases, or too approximate to yield high-quality tests. This paper models the state of a reconfigurable scan network with a finite state automaton, using the length of the active path as the output alphabet and the configurations as input symbols. Permanent faults are represented as incorrect transitions, and a greedy algorithm is used to generate a functional test sequence able to detect all these multiple state-transition faults. The automaton’s state set and the input alphabet are small subsets of the possible ones, and are carefully chosen. Experimental results on ITC’16 benchmarks demonstrate that the proposed approach is broadly applicable; the test sequences are more efficient than the ones previously generated by search heuristics

Fault-Independent Test-Generation for Software-Based Self-Testing

Software-based self-test (SBST) is being widely used in both manufacturing and in-the-field testing of processor-based devices and Systems-on-Chips. Unfortunately, the stuck-at fault model is increasingly inadequate to match the new and different types of defects in the most recent semiconductor technologies, while the explicit and separate targeting of every fault model in SBST is cumbersome due to the high complexity of the test-generation process, the lack of automation tools, and the high CPU-intensity of the fault-simulation process. Moreover, defects in advanced semiconductor technologies are not always covered by the most commonly used fault-models, and the probability of defect-escapes increases even more. To overcome these shortcomings we propose the first fault-independent method for generating software-based self-test procedures. The proposed method is almost fully automated, it offers high coverage of non- modeled faults by means of a novel SBST-oriented probabilistic metric, and it is very fast as it omits the time-consuming test- generation/fault-simulation processes. Extensive experiments on the OpenRISC OR1200 processor show the advantages of the proposed method

A Novel Sequence Generation Approach to Diagnose Faults in Reconfigurable Scan Networks

With the complexity of nanoelectronic devices rapidly increasing, an efficient way to handle large number of embedded instruments became a necessity. The IEEE 1687 standard was introduced to provide flexibility in accessing and controlling such instrumentation through a reconfigurable scan chain. Nowadays, together with testing the system for defects that may affect the scan chains themselves, the diagnosis of such faults is also important. This article proposes a method for generating stimuli to precisely identify permanent high-level faults in a IEEE 1687 reconfigurable scan chain: the system is modeled as a finite state automaton where faults correspond to multiple incorrect transitions; then, a dynamic greedy algorithm is used to select a sequence of inputs able to distinguish between all possible faults. Experimental results on the widely-adopted ITC'02 and ITC'16 benchmark suites, as well as on synthetically generated circuits, clearly demonstrate the applicability and effectiveness of the proposed approach: generated sequences are two orders of magnitude shorter compared to previous methodologies, while the computational resources required remain acceptable even for larger benchmarks