Transcript Chapter 12
Chapter 12 Field Programmable Gate Array Testing EE141 System-on-Chip Test Architectures 1 Ch. 12 - FPGA Testing - P. 1 What is this chapter about? Field Programmable Gate Arrays (FPGAs) Have become a dominant digital implementation media Reconfigurable to implement any digital logic function Focus on Testing challenges due to programmability and complexity Overview of testing approaches Test and diagnosis of various resources New frontiers in FPGA testing EE141 System-on-Chip Test Architectures 2 Ch. 12 - FPGA Testing - P. 2 FPGA Testing Overview of FPGAs Architecture, Configuration, & Testing Problem Testing Approaches BIST of Programmable Resources Logic Resources – Logic Blocks, I/O Cells, & Specialized Cores – Diagnosis Routing Resources Embedded Processor Based Testing Concluding Remarks EE141 System-on-Chip Test Architectures 3 Ch. 12 - FPGA Testing - P. 3 Field Programmable Gate Arrays Configuration Memory Programmable Logic Blocks (PLBs) Programmable Input/Output Cells Programmable Interconnect Typical Complexity = 5 million – 1 billion transistors EE141 System-on-Chip Test Architectures 4 Ch. 12 - FPGA Testing - P. 4 Basic FPGA Operation Writing configuration memory (configuration) defines system function Input/Output Cells Logic in PLBs Connections between PLBs & I/O cells Changing configuration memory data (reconfiguration) changes system function Can change at anytime Even while system function is in operation – Dynamic partial reconfiguration EE141 System-on-Chip Test Architectures 11100110100010001001010100010111 0001010010101010100100100010001 01010010010011001001000011110001 1001010001000011001000101000100 1001001000101001010101001001001 0100010100101000101001010010001 0010101011101010101010101010101 01011110111110000000000000011010 01111100001001110000011100100101 00000000111110010010001010011100 10010100001111000111000100101010 1010101010101001010010101010010 0101010101010101001001001 5 Ch. 12 - FPGA Testing - P. 5 FPGA Architectures Early FPGAs NxN array of unit cells – Unit cell = CLB + routing Special routing along center axes I/O cells around perimeter Next Generation FPGAs MxN array of unit cells Added small block RAMs at edges PC More Recent FPGAs Added larger block RAMs in array Added multipliers Added Processor Cores (PC) PC PC Latest FPGAs Added DSP cores w/multipliers I/O cells along columns for BGA EE141 System-on-Chip Test Architectures PC 6 Ch. 12 - FPGA Testing - P. 6 Combinational Logic Functions Gates are combined to create complex circuits Multiplexer example If S = 0, Z = A If S = 1, Z = B Common digital circuit Heavily used in FPGAs – Select input (S) controlled by configuration memory bit EE141 System-on-Chip Test Architectures A S Z B Truth table SAB Z 000 0 001 0 010 1 011 1 100 0 101 1 110 0 111 1 Logic symbol A B 0 Z 1 0 S1 7 Ch. 12 - FPGA Testing - P. 7 Look-up Tables Using multiplexer example Configuration memory holds truth table Input signals connect to select inputs of multiplexers to select output value of truth table for any given input value EE141 System-on-Chip Test Architectures Multiplexer 0 0 A 0 1 B 0 1 Z 1 S 0 1 1 1 0 0 0 1 Z 1 0 1 0 1 1 0 0 1 1 1 B 0 A Truth table SAB Z 000 0 001 0 010 1 011 1 100 0 101 1 110 0 111 1 1 S 8 Ch. 12 - FPGA Testing - P. 8 Basic Prog. Logic Block (PLB) Structure Look-up table (LUT) for combinational logic Store truth table in LUT (typically 3 to 6 inputs) Some LUTs can also act as RAM/shift register Flip-flops for sequential logic Programmable clock enable, set/reset Special logic Large logic functions with Shannon expansion Fast carry for adders and counters carry out Input[1:4] 4 LUT/ RAM Control clock, enable, set/reset EE141 System-on-Chip Test Architectures3 Carry & Control Logic carry in Flip-flop/ Latch Output Q output 9 Ch. 12 - FPGA Testing - P. 9 Look-up Table Based RAMs EE141 System-on-Chip Test Architectures Address Decoder LUT mode Data In en0 performs read en1 operations en2 Address decoder In0 en3 In1 with write enable In2 en4 generates load en5 signals to latches for write operations en6 en7 Small RAMs but Write can be combined Enable for larger RAMs Write Address Normal 0 0 0 1 0 1 0 1 1 1 0 0 0 1 Z 0 1 1 1 0 0 1 1 In0 In1 In2 Read Address 10 Ch. 12 - FPGA Testing - P. 10 Input/Output Cells Bi-directional buffers Programmable for input or output signals Tri-state control for bi-directional operation Flip-flops/latches for improved timing – Set-up and hold times – Clock-to-output delay Pull-up/down resistors Routing resources Tri-state Control to/from internal Output Data routing resources Input Data Connections to core of array Programmable EE141 System-on-Chip Test Architectures Bidirectional Pad Buffer I/O voltage & current levels 11 Ch. 12 - FPGA Testing - P. 11 Interconnect Network Wire segments of varying length xN = N PLBs in length – Typical values of N = 1, 2, 4, 6, 8 Long lines Wire A config bit Wire B – xH = half the array in length – xL = full array in length Programmable Interconnect Points (PIPs) Transmission gate connects to 2 wire segments – Controlled by configuration memory bit Four basic types of PIPs EE141 System-on-Chip Test Architectures 12 Ch. 12 - FPGA Testing - P. 12 Programmable Interconnect Points Break-point PIP Connect or isolate 2 wire segments Cross-point PIP 2 nets straight through 1 net turns corner and/or fans out Compound cross-point PIP Collection of 6 break-point PIPs – Can route 2 isolated signal nets Multiplexer PIP Directional and buffered Main routing resource in recent FPGAs Select 1-of-N inputs for output – Decoded MUX PIP – N configuration bits select from 2N inputs – Non-decoded MUX PIP – 1 configuration bit per input 13 EE141 System-on-Chip Test Architectures Ch. 12 - FPGA Testing - P. 13 Recent Architectural Trends Addition of specialized cores: Memories – Single and dual-port RAMs – FIFO (first-in first-out) – ECC (error correcting codes) Digital signal processors (DSPs) – Multipliers – Accumulators – Arithmetic/logic units (ALUs) Embedded processors – Hard core (dedicated processors) With dedicated program/data memories Otherwise, programmable RAMs in FPGA used for program/data memories = PLBs = routing resources = special cores = I/O cells – Soft core (synthesized from a HDL) EE141 System-on-Chip Test Architectures 14 Ch. 12 - FPGA Testing - P. 14 FPGA Resources Types and sizes of resources vary with FPGA family Example: LUTs vary from 3-input to 6-input – 4-input LUTs are most common Typical ranges for some commercially available FPGAs FPGA Resource Logic Routing Specialized Cores Other Small FPGA Large FPGA PLBs per FPGA 256 25,920 LUTs and flip-flops per PLB 1 8 Wire segments per PLB 45 406 PIPs per PLB 139 3,462 Bits per memory core 128 36,864 Memory cores per FPGA 16 576 DSP cores 0 512 Input/output cells 62 1,200 Configuration memory bits 42,104 79,704,832 EE141 System-on-Chip Test Architectures 15 Ch. 12 - FPGA Testing - P. 15 Configuration Interfaces Master mode (Serial or Parallel options) FPGA retrieves configuration from ROM at power-up Slave (Serial or Parallel options) FPGA configured by external source (i.e., a P) Used for dynamic partial reconfiguration Boundary Scan Interface 4-wire IEEE standard serial interface for testing Write and read access to configuration memory Interfaces to FPGA core internal routing network Not available in all FPGAs clock PROM with Config Data data out EE141 System-on-Chip Test Architectures CCLK CCLK FPGA in Master Mode Din Dout CCLK FPGA in Slave Mode Din Dout FPGA in Slave Mode Din Dout 16 Ch. 12 - FPGA Testing - P. 16 FPGA Configuration Memory PLB addressable Good for partial reconfiguration X-Y coordinates of PLB location to be written – “Z” coordinate identifies which resources will be configured Frame addressable Vertical or horizontal frame – Vertical frames most common Access to all PLBs in frame – Only portion of logic and routing resources accessible in a given frame – Many frames required to configure PLBs & routing EE141 System-on-Chip Test Architectures 17 Ch. 12 - FPGA Testing - P. 17 Configuration Techniques Full configuration & readback Simple configuration interface – Automatic internal calculation of frame address Long download time for large FPGAs Partial reconfiguration & readback Only change portions of configuration memory with respect to reference design – Reduces download time for reconfiguration Requires a more complicated configuration interface – Command Register (CMR) – Frame Length Register (FLR) – Frame Address Register (FAR) – Frame Data Register (FDR) EE141 System-on-Chip Test Architectures 18 Ch. 12 - FPGA Testing - P. 18 Configuration Techniques Compressed configuration Requires multiple frame write capability – Write identical frames of config data to multiple frame addresses Extension of partial reconfiguration interface capabilities – Frame address is much smaller than frame of configuration data Reduces download time for initial configuration depending on – Regularity of system function design – % utilization of array Unused portions written with default configuration data EE141 System-on-Chip Test Architectures 19 Ch. 12 - FPGA Testing - P. 19 FPGA Testing Taxonomy Test Approach Attribute Test pattern application and output response analysis Internal (BIST) External System-level testing Off-line On-line System application Independent Dependent Logic Routing Target programmable resources Classification PLBs I/O cells Cores Local Global On-line test while system is operational Off-line test while system is out-of-service Application-dependent testing tests only those FPGA resources used by intended system function Application-independent testing tests all FPGA resources EE141 System-on-Chip Test Architectures 20 Ch. 12 - FPGA Testing - P. 20 FPGA Test Configurations More test configurations required for routing resources than for logic resources Data below from publications on actual test configuration implementations in commercial FPGAs FPGA Vendor Number of Test Configurations Series PLBs ORCA2C 9 27 0 ORCA2CA 14 41 0 [Abramovici 2001] [Stroud 2002b] Atmel AT40K/AT94K 4 56 3 [Sunwoo 2005] Cypress Delta39K 20 419 11 [Stroud 2000] 4000E/Spartan 12 128 0 4000XL/XLA 12 206 0 Virtex/Spartan-II 12 283 11 [Dhingra 2005] Virtex-4 15 ? 15 [Milton 2006] Lattice Xilinx EE141 System-on-Chip Test Architectures Routing Cores Reference [Stroud 2003] 21 Ch. 12 - FPGA Testing - P. 21 A Simple PLB Architecture Two 3-input LUTs Can implement any 4-input combinational logic function Can implement full adder – Carry in LUT C – Sum in LUT S 1 flip-flop – Active levels – Clock edge – Set/reset 22 configuration memory bits D2-0 LUT LUT C 8x1 D2-0 3 Programmable: C7 C6 C5 C4 C3 C2 C1 C0 111 110 101 100 011 010 001 000 out Cout Smux SOmux 0 Sout 1 0 1 LUT S 8x1 D3 0 1 CB5 CEmux CB3 Clock Enable SRmux 0 1 CB4 FF Set/Reset Clock 8 per LUT – C7-C0 and S7-S0 CB CB0 CB1 CB2 = Configuration Memory Bit 6 control bits – CB5-CB0 EE141 System-on-Chip Test Architectures 22 Ch. 12 - FPGA Testing - P. 22 Test Configurations for Simple PLB All configuration memory bits must be tested for both logic values (0 and 1) assuming exhaustive input patterns Output effects for each logic value must be observed Exclusive-OR (XOR) and exclusive-NOR (XNOR) functions are good for testing LUTs Put opposite functions in adjacent LUTs to produce opposite logic values at inputs to subsequent logic functions Fault coverage results below are based on collapsed single stuck-at gate-level fault model (174 faults total) Configuration Bits Configuration #1 Configuration #2 Configuration #3 LUT C (C7 - C0) XNOR (01101001) LUT S (S7 - S0) XOR (10010110) CB0 - CB5 000010 111110 000001 Individual FC 149/174 = 85.6% 149/174 = 85.6% 108/174 = 62.1% Cumulative FC 85.6% EE141 System-on-Chip Test Architectures XOR (10010110) XOR (10010110) XNOR (01101001) XNOR (01101001) 97.7% 100% 23 Ch. 12 - FPGA Testing - P. 23 BIST for FPGAs Basic idea: Program some logic resources to act as – Test pattern generators (TPGs) – Output response analyzers (ORAs) – Resources under test Logic resources as blocks under test (BUTs) Routing resources as wires under test (WUTs) Goal: Minimize number of test configurations to minimize download time – Download time dominates total test time EE141 System-on-Chip Test Architectures 24 Ch. 12 - FPGA Testing - P. 24 TPG and ORA Implementations TPG implementation depends on test algorithm May be implemented in different resources (see table below) Multiple TPGs prevent faulty TPG from escaping detection Lower bound on number of PLBs per TPG, TPLB = BIN NFF – BIN = number of inputs to BUT – NFF = number of FFs/PLB ORAs most efficiently implemented in PLBs Number of PLBs needed for ORAs, OPLB = (NBUT × BOUT) NFF – BOUT = number of outputs from BUT – NBUT = number of BUTs Resource Under Test TPGs ORAs PLBs PLBs or DSP cores PLBs LUT RAMs PLBs or DSP and RAM cores PLBs I/O cells PLBs or DSP and RAM cores PLBs Cores (memories, DSPs, etc.) PLBs PLBs Interconnect PLBs PLBs EE141 System-on-Chip Test Architectures 25 Ch. 12 - FPGA Testing - P. 25 TPG Algorithms Small logic functions (PLBs, IOBs) can be tested with pseudo-random test patterns LFSRs or counting patterns Large logic functions (RAMs, DSPs) require specialized test algorithms for high fault coverage Below are examples of typical RAM test algorithms Algorithm March Test Sequence March Y ↨(w0); ↑(r0, w1,r1); ↓(r1, w0, r0);↑(r0) March LR w/o BDS ↨(w0); ↓(r0, w1); ↑(r1, w0, r0, r0, w1); March LR with BDS ↑(r1, w0); ↑(r0, w1, r1, r1, w0); ↑(r0) ↨(w00); ↓(r00, w11); ↑(r11, w00, r00, r00, w11); ↑(r11, w00); ↑(r00, w11, r11, r11, w00); ↑(r00, w01, w10, r10); ↑(r10, w01, r01); ↑(r01) Notation: w0 = write 0 (or all 0’s), r1 = read 1 (or all 1’s) ↑= address up, ↓= address down, ↨ = address either way EE141 System-on-Chip Test Architectures 26 Ch. 12 - FPGA Testing - P. 26 Output Response Analyzers Comparison-based XOR with OR feedback from flip-flop BUTj output BUTk output shift data shift mode – Latches mismatches observed due to faults Results retrieval ORA with shift register BUTj output BUTk output – Requires additional logic Configuration memory readback – Read contents of ORA flip-flops Good with partial configuration memory readback capabilities EE141 System-on-Chip Test Architectures Pass/ Fail Pass/ Fail BUTj output1 BUTk output1 BUTj outputn BUTk outputn Pass/ Fail 27 Ch. 12 - FPGA Testing - P. 27 Logic Resource BIST Architectures Basic comparison Multiple TPGs drive alternating columns (rows) of blocks under test (BUTs) BUTs in center of array observed by 2 sets of ORAs and compared with 2 other BUTs BUTs along edges of array observed by only 1 set of ORAs – Some loss of diagnostic resolution Basic Comparison =TPG =ORA =BUT Originally used to test PLBs – Later used to test specialized cores EE141 System-on-Chip Test Architectures 28 Ch. 12 - FPGA Testing - P. 28 Logic Resource BIST Architectures Circular Comparison Multiple TPGs drive alternating columns (rows) of blocks under test (BUTs) All BUTs observed by 2 sets of ORAs and compared with 2 other BUTs Circular Comparison – Good diagnostic resolution Originally used to test specialized cores =TPG =ORA =BUT – Later used to test PLBs and I/O cells EE141 System-on-Chip Test Architectures 29 Ch. 12 - FPGA Testing - P. 29 Logic Resource BIST Architectures Expected Results comparison expected results test patterns Multiple TPGs – One set of TPGs drive BUTs – Other set of TPGs produce expected results for comparison with outputs of BUTs Expected Results BUTs observed by 1 set of ORAs and compared with expected results from TPGs – Simple diagnosis since failing ORA position indicates faulty BUT Good when expected results can be algorithmically generated easily =TPG =ORA =BUT – Example: RAM test algorithms Originally used to test RAM cores EE141 System-on-Chip Test Architectures 30 Ch. 12 - FPGA Testing - P. 30 Logic Resource Diagnostic Procedure 1. 2. 3. 4. Record ORA results; 1= failure indication. For every set of 2 or more consecutive ORAs with 0s, enter 0s for all BUTs observed by these ORAs; the BUTs are faultfree. For every adjacent 0 and 1 followed by an empty space, enter 1 to indicate BUT is faulty; continue while such entries exist. If an ORA indicates a failure but both BUTs monitored by the ORA are fault-free, one of the following conditions exist: A. B. C. 5. A fault in routing resources between one of the BUTs and the ORA, ORA is faulty, or There are more than 2 consecutive BUTs with equivalent faults (for circular comparison only); reorder circular comparison and repeat test and diagnostic procedure. Remaining BUTs marked as unknown may be faulty; reorder circular comparison or rotate basic comparison architecture by 90, repeat test and diagnostic procedure. EE141 System-on-Chip Test Architectures 31 Ch. 12 - FPGA Testing - P. 31 Diagnostic Procedure Examples Note that B4 and B5 have equivalent faults in Example A Circular comparison provides better diagnostic resolution Also indicates when more than 2 consecutive BUTs with equivalent faults (Example C) Example A Example B Example C BIST Architecture Basic Circular Basic Circular Basic Circular Diagnostic Step 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1 1 0 0 0 0 0 0 0 1 1 B1 O12 B2 O23 B3 O34 B4 O45 B5 O56 B6 O61 EE141 System-on-Chip Test Architectures 0 0 0 0 0 1 1 0 0 0 1 1 1 1 ? 0 0 1 1 0 0 0 0 0 0 0 0 1 1 0 1 1 0 0 0 0 0 0 0 1 1 1 1 1 ? 1 1 1 ? 0 1 0 0 0 1 1 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 0 0 0 0 1 1 1 1 1 1 1 1 1 1 1 0 0 1 1 1 0 0 1 0 0 0 0 0 1 0 0 0 0 0 0 32 0 0 Ch. 12 - FPGA Testing - P. 32 Testing Routing Resources Comparison-based BIST approach Developed for on-line FPGA BIST Testing restricted to routing resources for 2 rows or 2 columns of PLBs Small Self-Test AReas (STARs) Comparison-based ORA Later applied to off-line BIST Fill FPGA with STARs Tests run concurrently Diagnostic resolution to STAR Easier BIST development But more BIST configurations EE141 System-on-Chip Test Architectures TPG WUTs ORA STAR T T T T T FPGA O O O O O 33 Ch. 12 - FPGA Testing - P. 33 Testing Routing Resources TPG WUTs parity bit ORA Original parity-based BIST approach Parity bit routed over fault-free resources – What is fault-free until you’ve tested it? Modified parity-based approach N-bit up-counter with even parity, and N-bit down-counter with odd parity – Gives opposite logic values for Stuck-on PIPs & bridging faults Parity used as test pattern – N+1 wires under test Good for small PLBs – like our simple PLB example Make STARs as small as possible Better diagnostic resolution Easier BIST development EE141 System-on-Chip Test Architectures parity-check based-ORA TPG Par C1 C0 WUTs O R A + 34 Ch. 12 - FPGA Testing - P. 34 Testing Routing Resources Testing typically separated by routing resources Global - interconnects non-adjacent logic resources Local - interconnects adjacent logic resources and connects logic resources to global routing Additional test configurations swap positions of TPGs and ORAs to reverse direction of signal flow to test directional, buffered routing resources Multiplexer PIPs are a good example =TPG =ORA global routing EE141 System-on-Chip Test Architectures local routing PLB feed-through local routing adjacent PLBs 35 Ch. 12 - FPGA Testing - P. 35 Reducing Test Time Orient BIST architecture to configuration memory Align along rows/columns depending on FPGA structure Downloading BIST configurations Compressed configuration for initial download Partial reconfiguration for subsequent downloads – Reduce number of frames written between configurations Keep routing constant between BIST configurations Optimize order of BIST configuration application Retrieving BIST results Partial configuration memory readback – Eliminates ORA logic for scan chain Allows concurrent testing of more resources – Minimize number of frames to be read Dynamic partial reconfiguration – Read BIST results after a series of BIST configurations Slight loss in diagnostic resolution EE141 System-on-Chip Test Architectures 36 Ch. 12 - FPGA Testing - P. 36 Embedded Processor Based BIST New area of R&D in FPGA testing Basic idea: Embedded processor core – Hard or soft core Configures FPGA for BIST – Via internal configuration access port (ICAP) Alternative: download initial BIST configuration Executes BIST sequence = BUT = ORA – May provide TPG functionality Retrieves BIST results – May perform diagnostic procedure Reconfigures FPGA for subsequent BIST configurations Soft core requires two test sessions to test area occupied by processor core during first test session EE141 System-on-Chip Test Architectures Processor core, TPGs and interface to ICAP circuitry Test session #1 Processor core, TPGs and interface to ICAP circuitry Test session #2 37 Ch. 12 - FPGA Testing - P. 37 Embedded Processor BIST Overall reduction in total test time Algorithmic reconfiguration faster than external download – 10 to 25 times faster – Results below from actual implementation in commercial FPGA Can be loaded into processor program memory for on-demand BIST and diagnosis of FPGA Good for fault-tolerant applications where system function is reconfigured around diagnosed fault(s) Resource Function Download Execution Total time Download Routing Execution BIST Total time Total Test Time EE141 System-on-Chip Test Architectures PLB BIST External 7.680 sec 0.016 sec 7.696 sec 20.064 sec 0.026 sec 20.090 sec 27.786 sec Processor Speed-up 0.101 sec 76.0 0.085 sec 0.2 0.186 sec 41.4 0.110 sec 182.4 0.343 sec 0.075 0.453 sec 44.3 0.639 sec 43.5 38 Ch. 12 - FPGA Testing - P. 38 Concluding Remarks Growing use of FPGAs in systems and SOCs FPGA testing is necessary but difficult due to Programmability Complex programmable interconnect network Constantly growing size and changing architectures Incorporation of new and different specialized cores Test & diagnosis allows fault-tolerant applications New FPGA capabilities assist in testing solutions Dynamic partial reconfiguration and readback Configuration/reconfiguration by embedded processor cores EE141 System-on-Chip Test Architectures 39 Ch. 12 - FPGA Testing - P. 39