Experts At The Table: Rapid Prototyping
Friday, December 9th, 2011By Ed Sperling
System-Level Design sat down to talk about rapid prototyping with George Zafiropoulos, vice president of solutions marketing at Synopsys; Juergen Jaeger, senior product marketing manager at Cadence, and Howard Mao, senior product director at Springsoft. What follows are excerpts of that conversation.
SLD: In prototyping are you analyzing any physical effects such as power?
Jaeger: To a certain degree, yes. Our customers are starting to mimic power domains switching on and off for sequencing. It’s not really power analysis. There are capabilities in emulation to do that. But power sequencing can be done in rapid prototyping, and it makes sense because you have to go through so many variations for a mobile chip that the performance of a prototype comes in handy.
Zafiropoulos: It’s an activity-based analysis. It’s a proxy for power.
Jaeger: You switch regions on and off, which is one of the key reasons for low-power SoCs today.
SLD: Software has been ignored as a mechanism for both performance and efficiency within a chip. How much of that shows up in the prototyping?
Zafiropoulos: It does, particularly for applications where you can’t analyze the quality of the circuit’s behavior without seeing it work in real life. If you’re looking at a video graphics decompression algorithm, viewing that in ones and zeroes is very difficult. But if you can look at the image on a video display, are there artifacts? If there are none, but you can see it’s still being compressed and decompressed, then you know it’s acceptable quality and you can see how much circuit activity there is. How fast are you clocking this thing? How much peripheral access is there? What things are on and off? Is everything set so you’re getting the functionality you want but the right things are shut off or slow enough. There’s an optimization opportunity that you can’t take advantage of in almost any other way.
Jaeger: The performance of prototypes allows you to do some architectural exploration and figure out what should you put in hardware and software. What happens when you move things back and forth?
Mao: That’s true. If you have a unique IC where you have to wait for the RTL, you cannot do this architectural exploration at the end of the cycle. This allows you the chance to make changes early in the cycle, which can really help you.
Zafiropoulos: You also want to start writing software early and do some high-level model analysis, pre-RTL. It’s a different form of prototyping, primarily for the software engineer, but that’s becoming more mainstream.
SLD: What happens to prototyping in 3D stacks?
Zafiropoulos: I don’t see why it would be different. But having the ability to rapidly try different architectural implementations might be helpful because there might be thermal problems with the stack. So you might try a different clock rate or processor core and quickly validate the functionality with a prototype. Indirectly it might help. But it’s not clear there’s an obvious correlation. Still, a system in a die stack will be very big and you’re going to have everything from processors to CCDs and communications devices and video drivers—and you have to be able to do all that together and test it all.
SLD: Even with re-use of chips in a stack?
Zafiropoulos: That’s where the system validation prototype is useful, whether it’s derivatives or validating a change to a design. SoC stacked die are fairly complex, because they’re going to go into digital cameras and other devices where you have a lot of things going on. You want to see if it all works together. That’s a good application for prototyping.
SLD: How will prototyping differ at 20nm and 14nm?
Jaeger: It won’t help specifically with the 20nm issues, which are more silicon issues. It’s all about the functional image. Capacity is a consideration there. There will be big designs. We have to take a close look at where FPGA prototyping goes. If there are too many FPGAs, it becomes inefficient again, even if the software tool can handle it. But just because of the connections between the FPGAs, it will be very slow. It will run at emulation speed, so what’s the purpose of prototyping? To save a few dollars?
Zafiropoulos: The obvious corollary is that with more capacity come more processing elements on the die. You’re going to have more processors, more software, more need to run at high speed, more need to do system-level debug. It’s not the physics of the problem. It’s the scope of the device you’re building.
SLD: Can prototyping be used to divide and conquer, though?
Zafiropoulos: You can certainly do subsystem validation and testing and coding.
Jaeger: Today that’s the predominant use. Customers are introducing subsystems.
Zafiropoulos: And those subsystems tend to have fairly well-behaved boundaries. Otherwise you couldn’t hook them together. There will be standardized interfaces. You’ll be able to divide it.
Mao: Some customers connect different prototype boards as a subsystem. That can also help them verify different subsystems.
SLD: What’s the market uptake on prototyping?
Zafiropoulos: Prototyping has been around since they invented the soldering gun in one form or another. What’s happened, though, is the availability of really good commercial tools to make it more practical to do more complex prototyping is fueling growth. There’s a realization that to do large ASIC prototyping is an engineering project in itself to build that prototype. To connect one together isn’t so bad, but to build one from scratch is much more difficult. A lot of engineering teams want the benefit of the prototype but don’t want to design a platform. Many designers could build a platform from scratch, but why? It would take several engineers years to do.
Jaeger: Their core competency isn’t building a board with FPGAs on it. And you need to develop documentation. It’s really a product in the end. In terms of numbers, there is real hard market data for this. Nobody puts a $5,000 FPGA into a $500 laptop. We know that multi-thousand dollar FPGAs are used for prototyping. That gives you some data. And you can look into the number of ASIC design starts each year and assume that a certain percentage go through prototyping. Those percentages are pretty high these days. So you are somewhere in the $600 million range per year for FPGA prototyping. The good news for the EDA industry is that most of this is still spent by customers building their own boards. There is a lot of room for growth for EDA if we get it right with the tool flow and if we can show the value we provide.
Zafiropoulos: And the value of the tool flow has changed dramatically in the last five years. The functionality and capability of the commercial tools is way ahead of where it was, whether it’s compiling, partitioning, debugging or fundamental platforms themselves.
Mao: There are a lot of people doing custom boards. The commercial tools can help them be more productive.



