vlsi design cycle |
The Customer Requirements for an
IC chip can vary based on its real-time usage/application/operational conditions.
IC chips has evolved from SSI -> MSI -> LSI -> VLSI -> ULSI in few
decades, accommodating gates from 10’s to Millions & billions over few
decades. The EDA Tools have come into picture from various vendors to serve the
huge count design needs. In Today’s World, the Micro chips are used in
various areas like Personal computing,
Cloud storage, Cloud computing, Networking, Gaming, Artificial Intelligence,
Machine learning, Autonomous, Defence, Aerospace, Medical Screening, R&D,
Marketing, Trading, Agricultural advancements etc., Based on the customer
requirements, the system specifications are drawn. The system specifications
include the operating speed, arithmetic/logic operations capability, data bus width,
functional units & their interfaces to external communication. The
architecture is a block diagram describing all the operational units specifying
the actual data flow in the required clock cycles. Architectural design is documented
for every IC chip to maintain the versions & to convey the data operations,
data flow & data interfaces information to Logic/RTL designer’s team. The
Logic designer’s make use of the architectural design information to develop
the behavioural description model. The behavioural description model is written
using the HDL’s. The HDL is the Hardware description language and some of those
are vhdl (VHSIC HDL), Verilog & system Verilog HDL’s. The HDL’s allow the
designers to describe the logic behaviour in various flow modelling –
concurrent (data flow), Behavioural, Structural, Mixed-flow & Gate-level modelling.
The behavioural description model is written using the Verilog HDL constructs
like always, initial, begin, end etc., to loop the data capture/operations at required
clock cycles. The Behavioural description model is process & technology
independent. This model can be re-used for other process & technology node.
The RTL model is the Register transfer Level which contains the data flow
through registers (sequential elements). Behavioural description model is translated
to RTL model using EDA tools. After developing the RTL code, the functional verification
(simulation) is carried with input waveform combinations to predict the output
desired waveforms using the simulation tools available.
The RTL code post-verification is
consumed for logic synthesis. The logic synthesis is the process of obtaining a
gate-level netlist (structural netlist) from the given RTL. Synthesis tools
perform the translation of RTL (in HDL) to tool specific gates. The translated
tool specific gates are then mapped to the targeted process & technology
specific gates of std cell library. Later, translation & mapping, the
optimization is carried on the design to achieve better performance in terms of
timing/area/power. Post synthesis the formal verification is carried to check the
RTL to obtained gate-level netlist for logical equivalency. The formal
verification tools based on the mathematical algorithms that builds logical cones
to prove logical equivalency between RTL to gate-level netlist. The Floorplan
is the placement of hard macros (comes from external IP team/owner), ports
(external interface) & tracks/boundary of block initialization. The power
planning is carried along with floorplan to deliver the power to std cell rails
(follow pins) from the Top power stripes that hook to the external power rings.
The placement is carried post floorplan
for placing the soft logic physically to obtain better control in
area/power/timing/congestion. The soft logic is the collection of standard cell
gates which are flexible to undergo optimizations. The hard logic is the
collection of hard macros which can be digital IP or analog IP that can’t
undergo any optimization at back-end. Post placement, CTS is the clock tree synthesis
that builds the physical clock to all the sequential in the design. The two
aspects that are focused here is Clock Skew & Clock latency (insertion
delay). The Route builds the physical paths with metal layers for all the
signal connections other than clock. Post-route the STA (static timing
analysis) is carried to perform setup/hold synchronous timing checks &
recovery/removal asynchronous checks. The Formal Verification will once again
be carried post-route to ensure logic equivalency. The Main stages of APR/PnR
flow are Place, CTS & Route. At these 3 stages, optimization is carried out
to attain better performance in terms of power/area/timing. The optimizations
are cell up/downsizing, logical restructuring, buffering to split fanout,
cloning to balance load, routing in higher layers/widths, shielding for
crosstalk reduction, legalization of cells etc., The ECO implementation include
the minor changes in design followed by selective routing to improve the
timing/area/power. DRC/layout verification is carried out to rectify the design
aspects and loop any feedback to APR/PnR level. DRC’s are the design rule
checks from the fab (PDK) to obtain better manufacturing yields. The
fabrication of the IC chip is the crucial step that lets the physical IC tape
out for real time usage. Fabrication is the most costliest process that happens
chemically by growing the CMOS/FINFET transistor by doping n or p type
impurities on the silicon wafer. The layout (either GDSII or OASIS) is the
input for the fab. After fabrication the
post-silicon validation is carried out to detect the manufacturing defects such
as electrical faults using the pre-existing scan chains (DFT) & functional
defects using test patterns & software OS booting & thermal operating
conditions etc., This validation process is little time consuming and it is the
last stage to capture all the defects for Re-Spin/bulk volume production of IC
chip. Re-Spin is going back to VLSI flow to rectify the faults either in RTL or
APR/Pnr. The Bulk volume production is to get IC chips in huge quantity for
marketing/delivering to customers.
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