Porting / Transferring FPGAs Design to ASICs

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The electronic forum deals with the topics related to analog and digital circuits and systems (i.e. ASIC, FPGA, DSPs, Microcontroller, Single/Multi Processors, PCBs etc) and their programming such as HDL, C/C++, etc.

Porting / Transferring FPGAs Design to ASICs

Unread postby UCERD.COM » Thu Nov 06, 2014 10:40 am

Field-programmable gate arrays (FPGAs) are a valuable technology for designing and prototyping digital logic into today’s applications. However, high FPGA unit cost can sometimes prohibit higher volume production. Several alternatives exist for transferring a digital design, implemented with an FPGA, into higher-volume production. Low-cost solutions such as structured application-specific integrated circuits (ASICs), cell-based ICs, and gate arrays offer higher performance, lower power consumption, higher levels of integration, and better response to radiation effects. The idea of migrating an FPGA design into an ASIC can be overwhelming to a design team, but careful planning and partnering with an experienced ASIC vendor can significantly ease the process.


Designing a new product in an FPGA allows for design modifications to be made quickly in hardware. Once the design code is stable and the product is ready for production, a migration from an FPGA to an ASIC can cut the production unit cost by up to 50%. The low non-recurring engineering (NRE) charges associated with a mid-range ASIC solution coupled with a much lower unit price point make this strategy a powerful tool in achieving low overall expense, giving users a competitive cost advantage in the market.

To help ease the migration process, designers must consider several items during the initial design phase:
  1. Today’s designs are larger, more complex, and contain more specialized intellectual property (IP) than ever before. Careful selection of IP early in the design phase is essential.
  2. Developing the FPGA and ASIC in a parallel design flow will help speed up the migration process.
  3. Planning for portability to an ASIC from the beginning will help shorten the time to market and decrease development cost.
  4. Good coding practices such as the use of synchronous design techniques will enable the architecture to be ported across many different technology platforms.
  5. Documentation is essential. If a little time and effort is used in the early stages of the design, the migration will require minimal engineering resources.

The migration can result in a drop-in replacement alternative that is footprint compatible to the FPGA. If the system can tolerate packaging and footprint flexibility, designers can attain further cost reduction.

Complex systems may require several FPGAs to prototype a complete system-on-a-chip (SoC) design. ASICs offer better gate density than FPGAs, as well as better core performance. This allows multiple FPGAs to be combined into a single SoC ASIC, saving expensive board real estate. If the architecture will not allow for full integration, a multi-personality ASIC can be produced to emulate the different FPGAs, allowing for a direct functional drop in replacement. This will optimize cost savings by reducing the ASIC tooling charges.

Parallel design flow
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Parallel design flows allow the designer to compress the ASIC development schedule (see figure 1). Prototyping in an FPGA enables engineering teams to verify functionality prior to ASIC implementation. It also provides a path for early hardware and software validation. In this design flow, the register transfer level (RTL) is developed and targeted to the FPGA and provided in parallel to the ASIC vendor for review and analysis. This allows the ASIC vendor to offer recommendations and modifications to the code to enhance robustness. Timing scripts and clocking architectures are developed for both the FPGA and ASIC. Package selection for the ASIC is determined along with signal integrity and power dissipation analysis. The printed circuit board (PCB) can be developed at this time to handle the larger power-hungry FPGAs with an identified path for migration to a smaller, more efficient ASIC package.

One option is to place the ASIC design on hold pending the final FPGA verification, or ramp-up to production. More commonly, the ASIC team begins logical design activities once the base architecture is fixed, IP requirements are defined, and pin out is fixed. Early ASIC development may also include development of the design for test (DFT) structures, script development for static timing analysis (STA), initial floor planning, and cell placement. Any major changes to the design can be quickly evaluated in the ASIC flow to ensure that the scripts for DFT and timing do not require modification. The final timing convergence and physical design flow wait until the design is ready to move to the ASIC.

Follow industry RTL coding standards
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RTL coding style largely determines several key aspects of the design, including architecture, testability limitations, area, timing performance, and power dissipation. The RTL coding style may also result in RTL and gate-level simulation mismatches, since logic simulators and logic synthesizers may interpret the RTL code differently. It is best to code the design RTL to meet industry standards.1 The design team should also verify the RTL code using one or more of the RTL rule checkers available in the marketplace.

Synchronous design techniques
A synchronous design can be ported to any technology node, providing it meets system performance requirements. A completely synchronous design is one that has a single master clock and a single master set/reset driving all sequential elements in the design. All input signals are synchronized to the clock so they never violate setup and hold times. Not many designs meet this rigid definition and often designs require multiple clock domains. Great care must be taken to synchronize data transfer between these domains by using either a handshaking protocol or first-in-first-out (FIFO) techniques. Gated clocks should be avoided unless low power requirements drive their implementation. If gated clocks must be used, designers should work closely with the ASIC vendor to prevent any potential glitches being generated on the clock lines. It is also best to think about design for test. Avoid the use of latches and combinational feedback loops and provide the ability to reset all sequential elements.

Packaging
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When designing in an FPGA, it is important for the design team to review package requirements and board layout. FPGAs use significantly more power than ASICs and may require a higher-performance package. The FPGA is also less efficient with core logic. If the design is placed into a larger FPGA family to accommodate the core logic requirements, the design may fit into a smaller pin count package once it is migrated to an ASIC. Package costs track with ball count and substrate performance. If the design can utilize a lower-performance industry standard package with lower ball counts, the device cost can be reduced dramatically. A drop-in replacement package can usually be provided, which will minimize any board rework and provide no or limited change to the system for software and hardware.

Information required for conversion
The information required by the ASIC vendor varies depending on the technical requirements of the design. In general, the more information provided, the better picture of the design the ASIC team will have. Minimum requirements include:

  • Intended ambient operating temperature
  • Desired core voltage
  • Pad voltage(s)
  • Specification of inputs, outputs, and bi-directional signals
  • Identification of transceiver requirements such as type (LVDS, HSTL, SSTL, LVPECL), speed, and version
  • Memory (RAM, ROM) requirements
  • IP requirements (all relevant IP information such as name, brief description, quantity, speed, and compatibility to existing standards, vendor, and licensing requirements)
  • Usage and purpose of timing IP blocks such as DLLs or PLLs
  • Package type
  • Design format (RTL, Verilog, VHDL, FPGA)
  • Timing requirements
  • Power Budgets

FPGAs provide a fast time-to-market and an efficient prototyping tool, but the high cost of mid-to high-end FPGAs can be prohibitive for volume production. With proper planning during the development phase, migrating the FPGA to an ASIC can be completed quickly without significant additional engineering effort.
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