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Fangming Ye · Zhaobo Zhang
Krishnendu Chakrabarty · Xinli Gu
Knowledge-
Driven
Board-Level
Functional
Fault Diagnosis
Knowledge-Driven Board-Level Functional
Fault Diagnosis
Fangming Ye Zhaobo Zhang
•
Knowledge-Driven
Board-Level Functional
Fault Diagnosis
123
Fangming Ye Krishnendu Chakrabarty
Huawei Technologies Department of Electrical and Computer
Santa Clara, CA Engineering
USA Duke University
Durham, NC
Zhaobo Zhang USA
Huawei Technologies
Santa Clara, CA Xinli Gu
USA Huawei Technologies
Santa Clara, CA
USA
vii
viii Preface
The authors acknowledge the support received from Huawei Technologies. The
authors also appreciate the contribution of Shi Jin to the work on handling missing
syndromes, described in Chap. 6.
ix
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Introduction to Manufacturing Test . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 System and Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 Testing in the Manufacturing Line . . . . . . . . . . . . . . . . 3
1.2 Introduction to Board-Level Diagnosis . . . . . . . . . . . . . . . . . . 6
1.2.1 Review of State-of-the-Art . . . . . . . . . . . . . . . . . . . . . . 7
1.2.2 Automation in Diagnosis System . . . . . . . . . . . . . . . . . 10
1.2.3 New Directions Enabled by Machine Learning . . . . . . . . 13
1.2.4 Challenges and Opportunities . . . . . . . . . . . . . . . . . . . . 15
1.3 Outline of Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2 Diagnosis Using Support Vector Machines (SVM) . . . . . . . . . . . . 23
2.1 Background and Chapter Highlights . . . . . . . . . . . . . . . . . . . . 24
2.2 Diagnosis Using Support Vector Machines . . . . . . . . . . . . . . . 25
2.2.1 Support Vector Machines . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2 SVM Diagnosis Flow . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 Multi-kernel Support Vector Machines and Incremental
Learning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.1 Multi-kernel Support Vector Machines . . . . . . . . . . . . . 29
2.3.2 Incremental Learning . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4.1 Evaluation of MK-SVM-Based Diagnosis System . . . . . 36
2.4.2 Evaluation of Incremental SVM-Based Diagnosis
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 37
2.4.3 Evaluation of Incremental MK-SVM-Based
Diagnosis System . . . . . . . . . . . . . . . . . . . . . . ...... 39
2.5 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 41
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... 42
xi
xii Contents
5.4 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.4.1 Demonstration of Syndrome Analysis . . . . . . . . . . . . . . 89
5.4.2 Demonstration of Root-Cause Analysis . . . . . . . . . . . . . 89
5.5 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6 Handling Missing Syndromes . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.1 Background and Chapter Highlights . . . . . . . . . . . . . . . . . . . . 95
6.2 Methods to Handle Missing Syndromes . . . . . . . . . . . . . . . . . . 97
6.2.1 Missing-Syndrome-Tolerant Fault Diagnosis Flow . . . . . 98
6.2.2 Missing-Syndrome-Preprocessing Methods . . . . . . . . . . 98
6.2.3 Feature Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.3 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
6.3.1 Evaluation of Label Imputation . . . . . . . . . . . . . . . . . . 107
6.3.2 Evaluation of Feature Selection in Handling Missing
Syndromes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3.3 Comparison of Different Missing-Syndrome Handling
Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.3.4 Evaluation of Training Time . . . . . . . . . . . . . . . . . . . . 114
6.4 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
7 Knowledge Discovery and Knowledge Transfer . . . . . . . . . . . . . . 121
7.1 Background and Chapter Highlights . . . . . . . . . . . . . . . . . . . . 121
7.2 Overview of Knowledge Discovery and
Transfer Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
7.3 Knowledge-Discovery Method . . . . . . . . . . . . . . . . . . . . . . . . 124
7.4 Knowledge-Transfer Method . . . . . . . . . . . . . . . . . . . . . . . . . 128
7.5 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
7.5.1 Evaluation of Knowledge-Discover Method . . . . . . . . . . 138
7.5.2 Evaluation of Knowledge-Transfer Method . . . . . . . . . . 138
7.5.3 Evaluation of Hybrid Method . . . . . . . . . . . . . . . . . . . 139
7.6 Chapter Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
8 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Chapter 1
Introduction
This section presents some basic definitions that are used in system test and diagnosis
[5, 6].
Definition 1 is quite general and it can be adopted to cover a set of different types of
systems in different fields of engineering, from digital systems to computer networks,
nuclear facilities, and chemical plants [5, 6].
In the reliability literature [7], there is a distinction between defects, which corre-
spond to locations of a system instance containing a difference between specification
and implementation, faults, defined as the actual causes of a system misbehavior, and
failures, representing the external observable effects of a fault, producing a deviation
of functionality from specifications.
In order to describe the diagnosis process, some additional definitions are needed,
covering both the targets of this process (components) and the information required
to be collected to execute diagnosis (tests). These concepts will be introduced later.
Let CS = {c1 , c2 , c3 . . .cn } be the set of all components that constitute system S.
A component containing (at least) one fault is referred to as a root-cause component;
every other component is fault-free.
Definition 4 requires that each component must be identified unambiguously
within the system. An extension of Definition 2 is that a fault can affect only one
component, and two components of a system cannot overlap.
According to the above definitions, a component can correspond to a physical
device in the system (e.g., a memory chip in a digital system). However, this condition
is not strictly required. A component can also refer to a group of physically connected
elements within the system, or even a set of noninterconnected entities contained in
a system (virtual component).
Let TS = {t1 , t2 , t3 . . . tn } denote the set of all tests used for system S, also
referred to as Test Suite. In general, testing a system can be described as the operation
1.1 Introduction to Manufacturing Test 3
Syndromes can provide detailed information about the output values of a circuit
[8] or system parameters (e.g., the value of a sensor measurement [9]). In some
cases, the information can be compacted in some form in order to keep only its
most significant part, e.g., the correspondence between the observed value of the
parameter and its expected one. When maximally compacted, a test outcome is a
binary variable that takes the value pass or fail.
• Definition 8. A root cause is the faulty component that leads to the failure of
system S.
The isolation of a root cause is achieved on the basis of the syndromes observed
for some or for all tests TS . These syndromes contain the information that can be
used to reveal the cause of misbehavior in system S.
A common assumption adopted in diagnosis is the so-called single fault hypoth-
esis. This assumption is necessary in order to reduce the complexity of considering
an exponential number of fault combinations to describe all possible system failures.
According to this assumption, any instance of a system can contain at most one
root-cause component.
Manufacturing test ensures that electronic products have no defects before they are
shipped to customers. Each fabricated product is subject to manufacturing test. The
process of manufacturing test is described as the explanation or interpretation of a set
of failure symptom [10], where a sequence of diagnostic tests is selected efficiently
to locate the root causes of failures. A diagnosis strategy has to tackle the following
fundamental issues [11]:
• Detection, i.e., the capability of a combination of tests to identify the presence of
a fault in a system.
• Isolation, i.e., the capability of a diagnostic strategy to achieve fine-grained local-
ization in order to allow the repair of a single component.
Compared to detection, isolation is a more difficult task in manufacturing test and
it is the main focus of this book. We use the term Diagnosis to refer to root-cause
isolation.
Diagnosis strategies vary across the different stages of system assembly. In order
to better understand the problems and challenges at the board level, let us first examine
chip-level testing. At the chip level, scan test is commonly used. In order to shift test
4 1 Introduction
patterns and response in and out of the chip, respectively, all the flip-flops are stitched
to one or multiple scan chains. Test patterns are generated by automatic test-pattern
generation (ATPG) tools and scanned into the circuit under test (CUT). The response
of the circuit is compared with the expected response. The circuit is deemed to be
fault-free if the test response matches the expected response. This testing process
can be performed on automatic test equipment (ATE).
A modern ATE is a complex equipment operating at GHz frequency and with
high throughput. The test cost on a high-end ATE can be up to thousands of dollars
per pin [6]. Therefore, test-data compression techniques have been widely explored
in the literature, in order to reduce the volume of test patterns and testing time. To
reduce dependence of an expensive ATE, built-in-self-test (BIST) techniques have
also been used [6]. In BIST, pseudo-random patterns are generated on-chip using a
pattern generation circuit, e.g., a linear-feedback shift register (LFSR). The on-chip
pattern generation approach eliminates the need for expensive external testers, and
makes high-speed test possible. However, the reliance on pseudorandom patterns to
achieve adequate fault coverage leads to a large volume of test data, compared to the
use of deterministic patterns generated by ATPG tools.
Chip-level test has been well studied in the past. The testing goal is straightforward
and quantifiable, i.e., to detect a high percentage of defects that are introduced during
manufacturing. The test environment (ATE) is well-understood and a given number
of pins are available for probing. Sophisticated tools and methodologies are available
for inserting effective design-for-testability (DFT) structures and for automatically
generating test patterns to get the desired fault coverage. This book focuses on the
testing and diagnostic problems at higher integration levels. Much less attention has
been devoted in the literature to these problems.
Circuit boards consist of previously tested components. An important objective
of board testing is to verify the printed wiring and the contacts between wires and
components. Moreover, the at-speed interactions between the components must also
be tested. A typical manufacturing test line of electronic systems is shown in Fig. 1.1.
Testing starts on the left-hand side of the figure. On the right-hand side, completely
tested products are placed in inventory or shipped to customers. The testing process
is separated into multiple stages to provide better failure isolation and feedback to
the manufacturing process.
Process test, such as automated optical inspection (AOI) and automated X-ray
inspection (AXI), is first applied to immediately catch process flaws, e.g., solder
shorts and unreliable solder joints. In-circuit test (ICT) is used to verify the perfor-
mance of individual components using a bed-of-nails fixture. The bed-of-nails fix-
ture is used to gain access to the board. ICT is useful to guarantee that a component
receives the correct value, since many board failures are caused by open/short circuits
or wrong components. Functional test, which targets the functional correctness of
components and the whole system, is typically run after process tests. Sometimes,
system test is performed as the final test, which is also a type of functional test. Each
test technique has its advantages. For example, the solder reliability can be easily
checked by AXI. The reversed or inoperative components can be detected by ICT.
No single test can, however, cover all possible defects.
With the development of high-density assembly on PCBs, the number of access
points for in-circuit test keeps decreasing. An interconnection test method, namely
boundary-scan test, has been widely adopted by manufacturers. The boundary-
scan architecture is defined in the IEEE 1149.1 and 1149.6 standards [12, 13] to
ensure connectivity between components. Simple boards and complex multiboard
systems can effectively be tested using the IEEE 1149.6 standard-compliant equip-
ment from the product design phase to mainstream manufacturing. At present, there
is an increased focus in the electronics industry on using the concept of remote
test and diagnosis in order to provide a mechanism that allows continued support
of a product [14]. The boundary-scan test architecture is illustrated in Fig. 1.2. A
boundary-scan cell, which includes a multiplexer and latches, is added to each pin
on the chip. Boundary-scan cells can capture data from pins or core logic signals, and
force data to pins. The test data is serially shifted into the boundary-scan cells. Then,
the captured data is serially shifted out and externally compared with the expected
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