Burn-In test equipment usually owns extensive memory capabilities to store pre-computed patterns to be applied to the circuit inputs as well as ad-hoc circuitries to drive and read the DUT pins during the BI phase. The solution proposed in this paper dramatically reduces the memory size requirement and just demands a generic microcontroller unit (MCU) equipped with a couple of embedded processors, some standard common peripheral units, and a few KB memories. Moreover, the proposed Burn-In tester could be integrated into a System Level Test equipment which is typically based on MCUs to communicate functionally with the DUT. This paper provides full details about the architecture of such a low-cost innovative tester, which can supply the DUT with unlimited pseudo-random patterns created autonomously by the MCU firmware from any selected seed. The tester prototype developed to collect experimental results includes a low-cost System-on-Chip based on a multi-core MCU and a set of peripheral cores, encompassing timers and Direct Memory Access modules. The tester prototype is used to stress an automotive chip accounting for about 20 million gates, 700 thousand scan flip-flops, and several scan modes. The combination of pseudo-random pattern generation with the ability to control different scan and Design for Testability (DfT) modes, including LBIST, permits to reach a higher coverage of stress metrics than by the application of a limited set of pre-computed ATPG patterns. The toggle coverage level reached is up to 95.89%. The application speed achieved by the tester with non-optimized connections is up to about 10MHz.

This paper encompasses three contributions by industry professionals and university researchers. The contributions describe different trends in automotive products, including both manufacturing test and run-time reliability strategies. The subjects considered in this session deal with critical factors, from optimizing the final test before shipment to market to in-field reliability during operative life.

The complexity of automotive Systems-on-a-Chip (SoCs) has enormously grown in the last decades. Today’s automotive SoCs are compelling due to technology improvements, different integration technologies, increased heterogeneity, and many available embedded memories. On balance, despite testing techniques that have been refined through years, traditional structural test methods, like scan and BIST, can cover a vast but not complete spectrum of all the possible defects. It appears that the divide-and-conquer approach founded on structural techniques may not be enough to reach every single element or to effectively stimulate the faulty behaviors that may show up during the lifetime of the device. Burn-In is widely used to reduce Infant Mortality, accelerating the evolution of weak points into defects via externally or internally induced stress.In this work, we focus on internal stress and present a generation strategy intended to automatically produce functional stress procedures for the Burn-In phase that exacerbate possible weak points which are likely to escape activation by structural tests, such that they more easily outbreak during the successive final test procedures. The proposed generation strategy primarily addresses the interconnections to embedded memories, which look challenging to stress by structural methods, including Logic and Memory BIST, and critical due to the integration of different technologies (i.e., logic gates and memory layout). In the considered test case, the proposed approach increases the average toggle activity by orders of magnitude with respect to Memory BIST. Furthermore, it provides a uniform distributed toggling activity.Results collected on an automotive SoC show how the stress provided by functional programs compares with the stress level provided by structural test methods measured in terms of toggling activity. The SpeedUp produced by the proposed procedure is 3.14X wrt to the MBIST executing the March C-algorithm.

Testing and validation check a hardware device or a software application against the desired design requirements. They are a vital part of all steps of system engineering and typically account for a significant percentage of the overall development cost. This paper presents a novel technique to provide a quick preliminary evaluation of functional test procedures of various natures, ranging from Software-Based Self-Test to Burn-In Functional Stress and System-level tests. We define a new metric called “connectivity”, which is fast to compute and can be used to guide functional program development. The method does not require logic or fault simulations, and it is based on the analysis of the execution trace generated by the functional program. To summarize our process, we first obtain the trace directly from the chip, running the software through a debugger. Then, we create a graph representation of the program data flow. Finally, we analyze the graph to identify instructions that negatively impact the final coverage. We perform experiments on an automotive device manufactured by STMicroelectronics, and we demonstrate the effectiveness of the approach in terms of computation time and beneficial effects on the fault coverage.

With the explosion of off-the-shelf SoCs in terms of size and the advent of novel techniques related to failure modes, commercial ATPG and fault simulation engines can often be insufficient to measure the coverage of very specific metrics. In these cases, many researchers firstly store the simulation trace during the analysis phase. Then, they collect the desired statistics during a post-processing step. In this framework, the so-called Value Change Dump (VCD) is a very commonly used file format to record simulation traces. The target of this paper is twofold. From the one hand, we illustrate some Burn-In (BI) related metrics which cannot be evaluated by current commercial fault simulators and ATPG engines. These metrics are indeed based on a post-processing analysis of memory dumps in VCD format. From the other hand, we mitigate the evaluation time and the memory required to analyze huge VCD files by exploiting optimization techniques coming from modern programming features and smart parallelization. Adopting this strategy, we can analyze simulation dumps of more than 250 GBytes in less than one hour, showing improvements of two orders of magnitude over previous tools, with a consequent higher scalability and testability power.

Automotive systems must reach a high reliability in their electronic components. This kind of devices must undergo several tests and stress steps discovering all possible defects that could manifest during lifetime. Burn-In (BI) is a manufacturing test phase used for screening the early life latent faults that can naturally affect a population of devices. System Level Test (SLT) is increasingly adopted as one of the final steps in the testing process of complex Systems on Chip (SoCs) mimicking the operational conditions. This paper aims at describing the motivations for and the effectiveness stemming from combining SLT with BI. The key idea leverages on the development of a new step inside the test process, which reproduces the system using SLT and places the system in the worst cases by means of the BI. Moreover, the paper analyses the required tester architecture to merge SLT and BI. Finally, an industrial case by STMicroelectronics is used to demonstrate the possible cost reduction.