Delay fault coverage, test set size, and performance trade-offs

The main disadvantage of the path delay fault model is that to achieve 100% testability every path must be tested. Since the number of paths is usually exponential in circuit size, this implies very large test sets for most circuits. Not surprisingly, all known analysis and synthesis techniques for 100% path delay fault testability are computationally infeasible on large circuits. We prove that 100% delay fault testability is not necessary to guarantee the speed of a combinational circuit. There exist path delay faults which can never impact the circuit delay (computed using any correct timing analysis method) unless some other path delay faults also affect it. These are termed robust dependent delay faults and need not be considered in delay fault testing. Necessary and sufficient conditions under which a set of path delay faults is robust dependent are proved; this yields more accurate and increased delay fault coverage estimates than previously used. Next, assuming only the existence of robust delay fault tests for a very small set of paths, we show how the circuit speed (clock period) can be selected such that 100% robust delay fault coverage is achieved. This leads to a quantitative tradeoff between the testing effort (measured by the size of the test set) for a circuit and the verifiability of its performance. Finally, under a bounded delay model, we show that the test set size can be reduced while maintaining the delay fault coverage for the specified circuit speed. Examples and experimental results are given to show the effect of these three techniques on the amount of delay fault testing necessary to guarantee correct operation