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Design Methodology for highly Reliable Digital ASIC Designs Applied to Network-Centric System Middleware Switch Processor Von der Fakultät für Mathematik, Naturwissenschaften und Informatik der Brandenburgischen Technischen Universität Cottbus - Senftenberg zur Erlangung des akademischen Grades Doktor der Ingenieurwissenschaften (Dr.-Ing.) genehmigte Dissertation vorgelegt von Diplom Ingenieur Vladimir Petrovic Geboren am 13.12.1982. in Pozarevac, Serbien, Jugoslawien Gutachter: Prof. Dr.-Ing. Rolf Kraemer Gutachter: Prof. Dr.-Ing. Heinrich Theodor Vierhaus Gutachter: Prof. Dr. Sergio Montenegro Tag der mündlichen Prüfung: 12.12.2013. Design methodology for highly reliable digital ASIC designs 1 Design methodology for highly reliable digital ASIC designs Acknowledgments I would like to express my sincerely gratitude to my supervisor Prof. Rolf Kraemer for support and opportunity to conduct my research work at the IHP through last years. While working in IHP I had support from many other colleagues and on this place I would like to thank them all. Before I express my gratitude to all people which were important during the thesis writing, I would like here specially to thank Prof. Dr. Vanco Litovski for the provided knowledge and support since 2001, when I started seriously to learn electronics. Specially thanks to Gunter Schoof and Ulrich Jagdhold for constructive discussions, interesting ideas and very helpful support during practical tests and thesis development. Dr. Zoran Stamenkovic put a lot of effort during thesis writing and he helped me a lot to bring a scientific form of the work provided in thesis. Therefore, I owe special gratitude to him and also to Dr. Michael Methfessel for support. I would like to thank Dr. Milos Krstic for very important discussions, thesis organization and great support in last years. The measurements and other tests would be impossible without Horst Frankenfeldt, Irina Matthaei, Silvia Hinrich, Christoph Wolf, Mahdi Khafaji and Florian Teply. I would like to express my sincerely gratitude to all of you. I would like to give my warmest thanks to my brother, parents, family and all friends, especially from KUD Kostolac for tremendous support all these years. This work is especially dedicated to my wife Danica. Her love, motivation and support have created the confidence that is needed to complete such a huge and complex task. Vladimir Petrovic 22.01.2014. 2 Design methodology for highly reliable digital ASIC designs 3 Design methodology for highly reliable digital ASIC designs Contents Abstract ................................................................................................................... 6 Zusammenfassung ................................................................................................. 7 1. Introduction ........................................................................................................ 8 2. Topic Definition and State-Of-The-Art .............................................................11 2.1. Irradiation Effects and Circuit Faults ........................................................11 2.2. SEU and SET Fault Models and Injection Techniques .............................13 2.3. SEL Model and Characterization ...............................................................17 2.4. Fault-Tolerant Circuits ................................................................................20 2.5. Standard Design Flow ................................................................................29 2.6. Open Issues .................................................................................................34 3. Fault-tolerant Circuits for Highly Reliable ASIC Designs ..............................35 3.1. Latchup Protection Circuits .......................................................................35 3.1.1. SPS Type 1 ........................................................................................38 3.1.2. SPS Type 2 ........................................................................................42 3.2. Redundant Circuits with Latchup Protection ...........................................45 3.2.1. TMR Circuit with Latchup Protection ..............................................45 3.2.2. Self-voting DMR Circuit with Latchup Protection ..........................51 3.3. Power Network Controller ..........................................................................57 4. Fault-Tolerant Circuit Simulation and Analysis ..............................................59 4.1. Fault Injection ..............................................................................................59 4.1.1. Transient Fault Library .....................................................................61 4.1.2. Upset Fault Library ...........................................................................63 4.1.3. Fault Injector .....................................................................................64 4.1.4. Fault Injection Mechanism ...............................................................67 4.2. Test Circuits ................................................................................................68 4.2.1. SET/SEU test circuits .......................................................................68 4.2.2. SEL test circuits ...............................................................................70 4.3. Simulation Results ......................................................................................73 5. Modified Design Flow and Circuits Implementation.......................................79 5.1. Modified Design Flow .................................................................................79 5.1.1. Netlist Parser ....................................................................................81 5.1.2. SPS cell automated placement and routing ...................................83 4 Design methodology for highly reliable digital ASIC designs 5.2. Implemented Test Circuits .........................................................................85 5.2.1. SPS network......................................................................................85 5.2.2. SPS cell .............................................................................................89 5.2.3. DMR Redundant Circuits with Latchup Protection ........................89 5.3. Results and Analysis ..................................................................................91 5.3.1. Power Network Controller ...............................................................91 5.3.2. Redundant circuits analysis ............................................................91 5.3.3. SPS cells analysis ............................................................................93 5.3.4. Measurements ..................................................................................96 6. A Case Study: Middleware Switch Processor ...............................................106 6.1. Introduction ...............................................................................................106 6.2. Middleware Switch Architecture ..............................................................108 6.2.1. Functional Description ...................................................................110 6.2.2. Middleware Switch Implementation ..............................................129 6.3. Fault-tolerant Middleware Switch Processor ..........................................131 6.4. Fault-tolerant MW Switch Implementation Characteristics ...................131 7. Conclusion .......................................................................................................135 Appendix A ...........................................................................................................137 Appendix B ...........................................................................................................141 Appendix C ...........................................................................................................147 Appendix D ...........................................................................................................150 Appendix E ...........................................................................................................152 References ...........................................................................................................159 List of acronyms ..................................................................................................165 Bibliography .........................................................................................................169 5 Design methodology for highly reliable digital ASIC designs Abstract The sensitivity of application-specific integrated circuits (ASICs) to single event effects (SEE) can lead to failures of subsystems which are exposed to increased radiation levels in space and on the ground. The work described in this thesis presents a design methodology for a fully fault-tolerant ASIC that is immune to single event upset effects (SEU) in sequential logic, single event transient effects (SET) in combinatorial logic, and single event latchup effects (SEL). Redundant circuits combined with SEL power switches (SPS) are the basis for a design methodology which achieves this goal. Within the standard ASIC design flow enhancements were made in order to incorporate redundancy and SPS cells and, consequently, enable protection against SEU, SET, and SEL. In order to validate the resulting fault-tolerant circuits