ASIC Design Flow

Himanshu Patel
Space Applications Centre (ISRO)
[email protected]
 Contents
o Introduction
o ASIC Design Methodologies
n Full custom
n Standard Cell
n Gate Array ASIC
n Structured ASIC
o ASIC Design Flow
n Design Entry
n Functional Verification
n Synthesis
n Design For Test (DFT)
n Place & Route
n Timing Verification
n Formal Verification
n Proto ASIC Test
o Mixed Signal ASIC
o Challenges for Deep Submicron ASIC
o CASE Study : OBC ASIC
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 ASIC
o ASIC stands for Application Specific
Integrated Circuits.
o It means an integrated circuit designed for
a specific application.
o An application could be a microprocessor,
cell phone, modem, router, etc.
o Nowadays, ASIC has a complete system on
it, often called as System on a Chip (SOC)

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 ASIC Design Methodologies

Full-custom Standard-cell Gate-array Structured

design based design based design ASIC
Ø Each Wafers are Wafers are
Standard
primitive logic pre-fabricated pre-fabricated
library cells
function or with with
(NAND,NOR,
transistor is unconnected Standard
XOR,FF etc)
manually gate arrays library cells
are used for
designed
design

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 Full custom ASIC

o Each primitive logic function or transistor is

manually designed
o Manually manipulation of each transistor geometry
is done, so also called “polygon pushing”
o Rarely used today, (except for very high volume
products like microprocessor etc)
Advantages:
o It gives most optimized design : high speed, low
power, small gate count
Disadvantage:
o Long design cycle
o Higher NRE (Non- Recurring Engineering) cost

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 Standard Cell based ASIC design

o Pre-defined library cells (NAND,NOR,FF,RAM, Hard macro

cores etc) are used
o Designs are created using schematic capture or synthesis
from Hardware Description Languages (HDL)
o All mask layers are customized —transistors and
interconnect

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 Standard cell ASIC
Advantages:
o Shorter design time compared to full custom style
o “Mega cells” or Hard IP cores (Microprocessor, MAC
Memory etc) provided by vendor can be used easily
Disadvantage:
o Separate fabrication mask is required for each
design : High NRE cost compared to gate array

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 Gate Array ASIC

o Wafers are pre-fabricated with unconnected gate

arrays (so wafers are common for all design)
o Top metallization for connecting transistors is done
according to different design at last stage

channeled gate array: channelless gate array:

The interconnect uses predefined Only some (the top few) mask layers
spaces between rows of base cells are customized

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 Gate Array ASIC
Advantages:
o Lower NRE cost as same base wafer is pre-fabricated
for multiple designs
o Low turn around time
Disadvantage:
o Low layout density,
o less optimized: Low speed, High power consumption
o Suitable only for lower volume products

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 Structured ASIC
o A Structured ASIC falls between an
Gate Array and a Standard Cell-
based ASIC
o The design task involves mapping
the design into a library of building
block cells, and interconnecting
them as necessary.
o Largely Prefabricated
n Components are “almost”
connected in a variety of
predefined configurations
n Only a few metal layers are
needed for fabrication
n Drastically reduces turnaround
time

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 Structured ASIC
Advantages:
o Low NRE cost
o High performance
o Low power consumption
o Less Complex
n Fewer layers to fabricate
o Small marketing time
n Pre-made cell blocks available for placing
Disadvantages:
o Lack of adequate design tools
o Design constrained by pre-fabricated block
available in library

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 Comparison Graph

Full Custom

Cost
Standard Cell

Gate Array FPGA

Volume

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 Digital ASIC Design Flow
1. Front End design :
o Specifications to Gate level netlist generation
o Normally done by customer
2. Back End design :
o From Gate Level netlist to GDS-II generation
o Normally done by vendor or third party designer
3. ASIC Fabrication:
o GDS-II to ASIC chip
o Done by foundry

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 Front End Design
Design Flow Verification Flow

Specifications

IP Cores
Design Entry Functional Verification Testbench
(RTL Coding) (Behavioral Simulation) coding

No Functionality
OK ?
BIST & JTAG
Yes
Insertion (DFT)
ASIC
cell Lib.
Synthesis
Netlist & SDF Pre Layout
Timing Simulation

Gate Level netlist

DRC
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DRC Error
 Specifications
o The chip functionality is described in
“Requirement & Specification Document”
o The targeted speed, power consumption,
area are also specified
o System Engineer conveys requirement in
plain English to Design team and
Verification team
n Design Team generates RTL code as per specs.
n Verification team generates Test benches/test
cases as per specs

Back
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 Design Entry
o Either by Scematic Capture or through
HDLs like VHDL,Verilog etc
o The quality of final chip depends largely on
quality of RTL code
o There are some design guidelines which
should be followed
n Design should be synchronous
n Clock gating should be avoided
n Flip flops should be used instead of latches
n Proper FSM coding styles (one hot, binary, etc)
o IP Cores or third party soft cores are used
for standard blocks like processor, MAC,
UART etc
Back
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 Testbench

Unit Under
Stimulus Test Output Test
Generator Monitor Report

o First Test plan is worked out based on which

different test cases are identified
o Assertion based testbenchs checks
captured output with expected output and
writes report
Back
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 Functional Verification

o The functionality of RTL code is verified using

testbenchs it is also called “behavioral Simulation”
o Some of the popular simulators :
n ModelSim®
n NCSim®
o Code coverage indicates how much portion of RTL
code is covered by testvectors
n Statement coverage
n Expression coverage
n Branch Coverage
n Toggle coverage
o Typically a “good” testbench achieves more than 95%
code coverage

Back
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 Design For Test
o Along with user logic, extra blocks are added
for detection of manufacturing defects
o DFT is “structural test” (unlike, Dynamic
simulation which is functional test)
o DFT methodology
n Built In Self Test (BIST)
RTL level
n Boundary Scan chain (JTAG)
n Internal Scan Chain Netlist level
o DFT Advantages:
n Improve quality by detecting defects
n Make it easier to generate vectors
n Reduce vector generation time
o DFT Disadvantages:
n Area overhead of 10-15%
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 BIST (Built In Self Test) Insertion
o Along with user logic, additional blocks are
added for self test
n Memory BIST (MBIST)
n Logic BIST (LBIST)

MBIST
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 JTAG Insertion
IEEE 1149.1 standard for Boundary Scan test

Back
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 Synthesis

o Process of converting RTL code in to gate

level netlist
o ASIC Vendor provides Cell library of basic
gates (AND,OR,FF,RAM,FIFO..)
o Pre synthesized IP Core blocks
(DesignWare,…) are treated as “Black Box”
o Some of the popular synthesizer :
n Synopsys DC, Cadence Ambit BuildGates
Synplify ASIC
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 o Synthesis Script contains directives for
synthesizer
n Optimization goal : speed/area
n Timing constraints
n FSM encoding style etc

o Special care should be taken for “high

fanout nets” like clock & reset
n They are not synthesized at this level
Set_dont_touch_network
n During Clock Tree Synthesis process, layout tool
creates optimized clock tree
Back
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 Pre Layout Timing Simulation
o Two types Timing Delays
n Cell delay (input to output of a cell)
n Propagation delay (o/p of cell1 to i/p of cell2)
o Delays are specified as (min, typ, max) depending
on PVT (Process, Voltage, Temperature) condition
o Wireload models are used to estimate
propagation delay based on fanouts
because at this stage Layout is not done
o Setup violations must be addressed
n Pipelining
n Register retiming (balancing combi. Logic)
o Hold violations can be ignored at this stage

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 Setup violation: Data late, clock early
Max delays are considered
Decides maximum clock frequency

Hold violation: Data early, clock late

Min delays are considered

Back
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 Design Rule Check (DRC)
o The gate level netlist must be checked for
“design rules” before starting Back End design
o There are different DRCs/LRCs
n Illegal net connections (two outputs shorted, etc)
n Drive load limit violations
o (fanout of driver < total load to output)
n Undriven nets
n Naming convention errors
o DRC tool kit is provided by ASIC foundry

Back
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 Back End Design
Design Flow Verification Flow
Gate Level netlist Testbench
Scan
Lib. Scan Insertion (DFT)

Floorplanning
Timing
Constr.
Placement

Pre Layout
Scan Chain Stitching & N/L
ATPG (DFT) Post Layout
N/L Formal Verification
Clock Tree Synthesis Equivalence check

Routing
STA Post Layout
Static Timing Analysis
Back Annotation SDF Timing Simulations
(RC Delay Extraction) Netist
Timing
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GDS-II file 27 No
 Scan Insertion (Design For Test)
o All internal flip-flops & latches are replaced by
Scan Flip-flops (FF with MUX)
o Testability
n Controllability
n Observability
o Scan Pins
n Scan In
n Scan Out
n Scan Enable
o scan cells are
NOT connected until
placement is completed
so ‘chain’ is not formed
at this stage
ASICBack
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 Floorplanning
o Floorplanning is a mapping between the
logical description (Hierarchical Netlist) and
the physical description (the floorplan).

The goals of floorplanning are to:

o arrange the blocks on a chip,
o decide the location of the I/O pads,
o decide the location and number of the
power pads,
o to minimize the chip area and delay

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 Floorplanning

initial random floorplan

generated by a
floorplanning tool

Blocks are moved to reduce

congestion

Back
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 Placement
o Placement is arranging all the logic cells within
the flexible blocks on a chip.

o objectives of placement
n Guarantee the router can complete the
routing step
n Minimize all the critical net delays
n Make the chip as dense as possible

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 block A contains four rows of standard cells (A.211, A.19, A.43, A.25)
The Goal is to decide placement to achieve minimum distance between cells

Back
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 Scan chain stitching & ATPG
o After placement , Scan cells are stitched
together to form a ‘scan chain’

o Normally Different scan chains are formed

for different clock domain Flip Flops

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 ATPG (Automated Test Pattern Generation)

q ATPG generates Test patterns/vectors which are applied to DUT

for detection of manufacturing defects

q The goal of ATPG is to create a set of patterns that achieves a

given (maximum) test coverage, Stuck at ‘0’ fault

q ATPG consists of two main steps:

qgenerating patterns
qfault simulation.
Fault models:
• Stuck-at-fault
• Transition fault : Propagation delay of cell
• Path delay : Sum of time delays in path
• IDDQ : Measurement of quiescent power supply
current during the stable state

Back
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 Clock Tree Synthesis (CTS)
o Clock Tree is defined by its startpoint (source) and
endpoints (sinks)
o During CTS, delay and skew from source to sinks are
optimized.
Step 1: Generate a clock tree
Step 2: Tune the clock tree to meet Skew & Slew target

Back
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 Routing
o Routing is done in 2 steps
n Global Routing : plans channels for routing between
blocks, Its goal are:
o Minimize the total interconnect length.
o Maximize the probability that the detailed router
can complete the routing.
o Minimize the critical path delay.

Global routing for a cell-based ASIC formulated as a graph problem.

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 Detailed Routing :
n complete all the connections between
logic cells
n exact location and layers for each interconnect
are determined

Completed channel route (2 metal layers m1 and m).

Back
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 Back Annotation & RC Extraction
o Delays are extracted from physical & RC
information in Standard Delay Format (SDF)
o Back annotated SDF file is used during post layout
timing simulation and STA.

The lumped-RC interconnect model.

Back
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 Formal Verification
o Equivalence check between pre-layout and
post layout
o Mathematical models are made to check
functionality equivalence at each node of
netlist
o FV can also be done between RTL & Netlist
o EDA Tool
n Formal Pro (Mentor)
n Formality (synopsis)

Back
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 STA (Static Timing Analysis)
• Static timing analysis is a method of validating the
timing performance of a design by checking all
possible paths for timing violations.
• STA tool breaks the design down into a set of
timing paths, calculates the signal propagation
delay along each path

o Compared with dynamic simulation, STA is much

faster because it is not necessary to simulate the
logical operation of the circuit.

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 STA - Timing Paths

Timing Paths :
o Input path (I/p pad to FF)
o Sequential path (FF to FF)
o Output path (FF to o/p)
o Combination path (i/p to o)

Back
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 Post Layout Timing Simulation
o Back annotated SDF with post layout netlist
is simulated at min, typ and max condition

o All interface timing (Ex. ROM/RAM access

timing, PCI bus timing etc) should be
modeled as Bus Functional Model (BFM)

o The simulation should be free from all

Setup and hold violation

o Whenever data is crossing clock domain,

metastable conditions should be checked.
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 Setup and Hold Checking

Back
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 Mixed Signal ASIC
o Digital + Analog blocks
o Analog blocks
n ADC, DAC
n Amplifiers, comparators etc
n RF Modulators & Demodulators

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 Mixed Signal ASIC Design Flow

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 Deep Submicron ASIC : Challenges
o As technology advances towards submicron
(below 0.13um/0.9um) issues like signal
integrity, power etc become prominent

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 Deep Submicron issues
n Power
o Increased DC power due to leakage
current
n Signal Integrity
o Lower supply voltage reduces noise
margin
o Smaller geometries induces
coupling noise
o Higher current density causes EM
issues
n Design Complexity
o Transistor Density doubles every
18 months (moor’s law)
o Clock frequency increases above 5
GHz

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 OBC ASIC : A Case Study
o OBC (On Board Controller) ASIC is designed for different
ISRO’s Satellite missions having on board Distributed
controllers

o OBC ASIC Features

n On chip 8051 micro controller soft core
n 4 UARTs, 3 Timers, 6 Interrupts
n 3 synchronous serial receivers & transmitters
n 10 ports for parallel I/Os
n On chip 1KB ROM containing monitor program
n 16 programmable timing signal generator

o ASIC Features
n CMOS Gate Array ASIC
n 256 pin package , 224 user I/Os
n 5 V core & 5V I/Os
n Radiation Hardened process
n Testability features like SCAN and ATPG with logic Fault
Coverage of > 95%
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 OBC Block Diagram

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 DW8051
Synopsys® DesignWare 8051
Soft IP Core

Features
o High–speed architecture
:4 clocks per instruction
cycle 2.5X improvement
over the standard 8051
o Dual data pointers
o 3 Timers, 2 UARTs
o Extended Interrupts (7 nos)
o Variable length MOVX to
access fast/slow RAM
peripherals
o Fully static synchronous
design

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 OBC Peripheral Modules
o Watch Dog Timer : generates
reset/interrupt whenever the software
hangs
o Delta Sigma ADC: 8 bit digitization of low-
rate analog data

o Programmable Combinatorial Logic

Module: A small FPGA CLB inside ASIC…!

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 o Timing Signal Generator: This is generic
timing signal generator, which can generate
up to 16 programmable pulses
o Auxiliary Data Interface: This is
parallel/serial auxiliary interface with built in
dual port RAM.
o Serial Synchronous
Transmitter/Receiver This is 3-wire (clock,
strobe, data) synchronous tx/rx
o Monitor Program :OBC ASIC contains 1K
Bytes of on chip ROM which holds Monitor
program firmware.
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 Event Programmable Parallel Interface

o In Phased array distributed controller it is required to

load Transmit & Receive characterization data within
time constraint as shown above
o This task was earlier implemented in software as
“Interrupt Service Routine”, but due to variable
interrupt latency it was not meeting timing constraint
o So a Hardware module was implemented

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 EEPPI - Architectute
clk
reset_n

Port0_PPI [7:0]
8
PPI Port1_PPI [7:0]
addr[7:0] 8
Micro-controller Register
Ports Port2_PPI [7:0]
din[7:0] RegisterBank
Bank 8
SFR 6Register
XX88Bits
6Register
Bank
Bank
MUX 6X8 Port3_PPI [7:0]
66XX8Bits
8Bits
Bits 48 bits 8
Interface dout[7:0] Port4_PPI [7:0]
8
48 Port5_PPI [7:0]
Sfr_wr 8
reg sel wr

2 1

Data out[2:0]
Flags
Look Up Table
(LUT) Addr 2
MUX Timing_control_Sig1
(Event -Action) Event
64 X 3 6 2
Detect Timing_control_Sig0
bits Module
2

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 UART_RRS

o UART with Recursive Running Sum Filter to

remove noise samples from incoming serial data

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 UART_RRS Test Results

o UART_RRS has better performance than standard UART at

higher Noise levels
n UART_RRS can decode data correctly up to 37% corrupted sample
n Standard UART can decode data up to 6 % only

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 Challenges Faced during OBC design
o Almost all OBC modules are programmable/
configurable because exact funtionality was not
freezed during front-end design.
o Multi Clock Domain
n OBC contains 7 clock domains so 7 Scan Chains were
inserted.
o Data crossing clock domains
n Asynchronous DPRAM, with Left and Right Ports
accessing data at different clocks
n Series of FFs to avoid Metastable condition
o Rad Hard cells
n All Flip flops used in OBC are radhard (ASIC library
contained Soft, Rad Tol. & Rad hard)
o Monitor Program
n On chip 1K ROM contains assembly software , which
was regorously tested as lateron software
modification was not possible

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 Proto ASIC Testing

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 Thank You

To Probe Further :
http://Geocities.com/hnpatel81/asic.htm

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