# LDPC Decoder Hardening Results ## Run 1: `26_02_25_21_11` (Feb 25, 2026) — FAILED - **RTL**: Original (unpipelined CN update) - **Config**: `CLOCK_PERIOD=20` (50 MHz), `RUN_HEURISTIC_DIODE_INSERTION=true`, `HEURISTIC_ANTENNA_THRESHOLD=110` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Failure**: `GRT-0118` routing congestion after heuristic diode insertion (66,016 diodes added) - **Notes**: Initial global routing passed (0 overflow, 39% routing utilization). Diode insertion nearly doubled cell count, causing re-routing congestion failure. ## Run 2: `reuse_synth` (Feb 27, 2026) — COMPLETED (timing violations) - **RTL**: Original (unpipelined CN update) — reused synthesis netlist from Run 1 - **Config**: `CLOCK_PERIOD=20` (50 MHz), `RUN_HEURISTIC_DIODE_INSERTION=false`, `RUN_ANTENNA_REPAIR=true` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Result**: All 70 steps completed. GDS generated. Deferred timing errors. ### Physical Results | Metric | Result | |--------|--------| | Magic DRC | **Clean** | | KLayout DRC | **Clean** | | LVS | **Clean** (0 errors, 0 unmatched) | | XOR (Magic vs KLayout) | **Clean** | | Illegal overlap | **Clean** | | Power grid violations | **0** | | Antenna violating nets | 658 | | Antenna violating pins | 905 | ### Area & Utilization | Metric | Value | |--------|-------| | Die area | 4,928,000 µm² (4.93 mm²) | | Core area | 4,846,670 µm² | | Instance count | 184,663 | | Instance area | 1,303,260 µm² (1.30 mm²) | | Core utilization | 26.9% | | Sequential cells | 16,967 | | Combinational cells | 61,366 | | Timing repair buffers | 23,709 | | Fill cells | 415,149 | | Tap cells | 69,228 | ### Timing (post-route, CLOCK_PERIOD = 20 ns / 50 MHz target) | Corner | Setup WNS (ns) | Setup TNS (ns) | Hold WNS (ns) | Hold TNS (ns) | Setup Violations | |--------|----------------|-----------------|----------------|----------------|------------------| | nom_tt_025C_1v80 | **-27.13** | -234.9 | -0.32 | -3.76 | 9 | | nom_ss_100C_1v60 | **-70.58** | -29,946.3 | 0.06 | 0 | 5,463 | | nom_ff_n40C_1v95 | **-10.18** | -86.3 | -0.26 | -12.4 | — | | **Worst across all** | **-71.40** | -34,329.1 | -0.47 | -26.4 | — | ### Estimated Max Frequency - **TT corner**: Critical path ~47 ns → **~21 MHz** - **SS corner**: Critical path ~91 ns → **~11 MHz** - **FF corner**: Critical path ~30 ns → **~33 MHz** ### Power (TT corner) | Component | Power (W) | |-----------|-----------| | Internal | 0.0554 | | Switching | 0.0273 | | Leakage | ~0.002 mW | | **Total** | **0.0827** | ### Key Observations 1. Disabling heuristic diode insertion fixed the routing congestion failure from Run 1 2. 658 antenna violations remain — iterative antenna repair was not sufficient. May need to re-enable heuristic insertion with a higher threshold or use `DIODE_ON_PORTS` 3. Setup timing is severely violated — critical path is ~47 ns at TT, far from 20 ns target 4. This run used the **unpipelined** RTL (synthesis reused from Run 1 which predated the CN pipeline split) 5. Next run should re-synthesize with pipelined CN update RTL to see if timing improves ## Run 3: `pipelined_pnr` (Mar 1, 2026) — FAILED - **RTL**: Pipelined CN update (CN_STAGE1 + CN_STAGE2) - **Config**: `CLOCK_PERIOD=20` (50 MHz), `SYNTH_STRATEGY=AREA 0`, `RUN_HEURISTIC_DIODE_INSERTION=false`, `RUN_ANTENNA_REPAIR=true` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Failure**: `GRT-0118` routing congestion during iterative antenna repair (step 36), after 13+ hours of repair loops - **Notes**: Iterative antenna repair kept inserting diodes and re-routing until congestion became too high. Same root cause as Run 1 but via different mechanism. ## Run 3b: `pipelined_synth` (Feb 28, 2026) — STILL RUNNING - **RTL**: Pipelined CN update - **Config**: `SYNTH_STRATEGY=AREA 2` — synthesis only - **Status**: ABC pass 2 (tech mapping) running 20+ hours. `AREA 2` is far too aggressive for this design size. **Do not use AREA 2 for this design.** ## Run 4: `pipelined_noantenna` (Mar 2, 2026) — COMPLETED (timing violations) - **RTL**: Pipelined CN update (CN_STAGE1 + CN_STAGE2) - **Config**: `CLOCK_PERIOD=20` (50 MHz), `SYNTH_STRATEGY=AREA 0`, `RUN_HEURISTIC_DIODE_INSERTION=false`, `RUN_ANTENNA_REPAIR=false` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Result**: All 69 steps completed. GDS generated. Deferred timing errors. No antenna repair attempted. ### Physical Results | Metric | Result | |--------|--------| | Magic DRC | **Clean** | | KLayout DRC | **Clean** | | LVS | **Clean** (0 errors, 0 unmatched) | | XOR (Magic vs KLayout) | **Clean** | | Illegal overlap | **Clean** | | Antenna violating nets | 1,707 (no repair attempted) | | Antenna violating pins | 3,319 (no repair attempted) | ### Area & Utilization | Metric | Value | |--------|-------| | Die area | 4,928,000 µm² (4.93 mm²) | | Instance count | 183,774 | | Instance area | 1,351,790 µm² (1.35 mm²) | | Core utilization | 27.9% | ### Timing (post-route, CLOCK_PERIOD = 20 ns / 50 MHz target) | Corner | Setup WNS (ns) | Setup TNS (ns) | Hold WNS (ns) | Hold TNS (ns) | |--------|----------------|-----------------|----------------|----------------| | nom_tt_025C_1v80 | **-28.86** | -348.0 | -0.08 | -0.15 | | nom_ss_100C_1v60 | **-74.22** | -20,536.0 | -0.07 | -0.07 | | nom_ff_n40C_1v95 | **-11.04** | -93.8 | -0.12 | -2.15 | | min_tt_025C_1v80 | -28.39 | -251.0 | 0 | 0 | | max_tt_025C_1v80 | -29.36 | -725.1 | -0.24 | -2.15 | ### Estimated Max Frequency - **TT corner**: Critical path ~49 ns → **~20 MHz** - **SS corner**: Critical path ~94 ns → **~11 MHz** - **FF corner**: Critical path ~31 ns → **~32 MHz** ### Power (TT corner) | Metric | Value | |--------|-------| | **Total** | **0.0858 W** | ### Key Observations 1. Pipelined CN update did NOT improve timing — TT WNS is -28.86 ns vs -27.13 ns (unpipelined Run 2). Slightly worse, possibly due to AREA 0 vs AREA 2 synth strategy difference. 2. Hold violations are much smaller than Run 2 (-0.08 vs -0.32 ns), nearly clean. 3. Antenna violations increased to 1,707 nets (vs 658 in Run 2) without any repair — AREA 0 produces a less antenna-friendly netlist. 4. The critical path is still ~47-49 ns, suggesting the bottleneck is NOT the CN update pipeline stage but something else (likely the large mux/barrel shifter or belief update logic). 5. `SYNTH_STRATEGY=AREA 2` takes 20+ hours for ABC tech mapping on this design — **never use it**. `AREA 0` completed in reasonable time. ## Summary Table | Run | RTL | Synth | Antenna | Status | TT Setup WNS | Max Freq (TT) | |-----|-----|-------|---------|--------|-------------|---------------| | 1 | Unpipelined | AREA 2 | Heuristic 110µm | **FAILED** (congestion) | — | — | | 2 | Unpipelined | AREA 2 | Iterative | **COMPLETED** | -27.13 ns | ~21 MHz | | 3 | Pipelined | AREA 0 | Iterative | **FAILED** (congestion) | — | — | | 3b | Pipelined | AREA 2 | — (synth only) | Still running (20+ hrs) | — | — | | 4 | Pipelined | AREA 0 | None | **COMPLETED** | -28.86 ns | ~20 MHz | ## Critical Path Analysis (from Run 4, pipelined_noantenna) ### Path Summary | Item | Value | |------|-------| | Startpoint | `u_core.beliefs[0][5]` (beliefs register, bit 5 of element 0) | | Endpoint | `syndrome_weight[7]` (MSB of syndrome weight counter) | | RTL location | `SYNDROME` state in `ldpc_decoder_core.sv`, lines 363-385 | | Slack | **-28.859 ns** (VIOLATED) | | Total combinational delay | **47.67 ns** | | Logic levels | **222** (171 XOR/XNOR + 51 adder/mux) | | Logic vs wire delay | 99.7% logic / 0.3% wire | All 8 worst setup violators fan out from `beliefs[0][5]` to `syndrome_weight[7:0]`. ### What the Critical Path Computes The `SYNDROME` state computes the full syndrome check in a **single clock cycle**: 1. **Parity computation** (171 XOR levels, 33.9 ns): XOR the sign bits of all beliefs connected to each check node — 7 rows x 32 z-elements x up to 3 columns = 224 parity bits, reading from 256 belief sign bits. 2. **Population count** (51 adder levels, 13.6 ns): Sum all 224 parity results into an 8-bit `syndrome_cnt`. The `syndrome_cnt = syndrome_cnt + 1` accumulation pattern creates a carry chain dependency that serializes everything. ### Delay Breakdown | Segment | Delay (ns) | Cells | Description | |---------|-----------|-------|-------------| | Source CLK-to-Q | 0.795 | 1 (dfxtp_4) | beliefs[0][5] register output | | Parity XOR chain | 33.888 | 171 (xor2/xnor2) | XOR reduction across belief sign bits | | Popcount adder tree | 13.634 | 51 (and/or/aoi/oai) | 224-bit popcount to 8-bit count | | State MUX | 0.148 | 1 (mux2_1) | FSM output mux | | Wire (interconnect) | 0.149 | — | 0.3% of total — negligible | | **Total** | **48.614** | **222 levels** | | ### Proposed Fix: 2-3 Stage Syndrome Pipeline **SYNDROME_S1** (cycle 1, ~16 ns): Compute all 224 parity bits in parallel. Each parity is only 2-3 XOR operations deep (one per connected column). Register the 224-bit `parity_vec`. **SYNDROME_S2** (cycle 2, ~14 ns): Popcount the 224-bit parity vector via balanced adder tree. Register the 8-bit `syndrome_weight` and `syndrome_ok` flag. **SYNDROME_DONE** (cycle 3): Already exists — reads `syndrome_ok`. **Estimated post-fix critical path**: ~14-16 ns (comfortably under 20 ns / 50 MHz). **Latency impact**: +1-2 cycles per iteration (negligible at 30 iterations). ### Secondary Violations Wishbone address input (`wb_adr_i`) has -2.47 ns setup violation. Fixable by registering the address at the decoder boundary. ## Run 5: `syndrome_pipeline` (Mar 3, 2026) — COMPLETED (timing violations) - **RTL**: Pipelined CN + syndrome pipeline (SYNDROME_S1 + SYNDROME_S2 with serial popcount) - **Config**: `CLOCK_PERIOD=20` (50 MHz), `SYNTH_STRATEGY=AREA 0`, `RUN_ANTENNA_REPAIR=false` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Result**: All 75 steps completed. DRC/LVS clean. - **TT Setup WNS**: **-28.98 ns** — no improvement from Run 4 - **Root cause**: Yosys serializes `syndrome_cnt = syndrome_cnt + 1` loop-carried dependency into ~48 ns chain - **Lesson**: Splitting parity + popcount into 2 cycles helps nothing if the popcount itself is still serial ## Run 6: `balanced_popcount` (Mar 4, 2026) — COMPLETED (TT timing MET!) - **RTL**: Pipelined CN + syndrome pipeline with balanced 4-wide adder tree popcount - **Config**: `CLOCK_PERIOD=20` (50 MHz), `SYNTH_STRATEGY=AREA 0`, `RUN_ANTENNA_REPAIR=false` - **Die area**: 2800 x 1760 µm (4.93 mm²) - **Result**: All 75 steps completed. DRC/LVS clean. **TT timing met!** ### Physical Results | Metric | Result | |--------|--------| | Magic DRC | **Clean** | | KLayout DRC | **Clean** | | LVS | **Clean** (0 errors, 0 unmatched) | | Antenna violating nets | 1,687 (no repair attempted) | ### Area & Utilization | Metric | Value | |--------|-------| | Die area | 4,928,000 µm² (4.93 mm²) | | Instance count | 186,915 | | Instance area | 1,367,580 µm² (1.37 mm²) | | Core utilization | 28.2% | | Sequential cells | 18,056 | | Timing repair buffers | 27,864 | ### Timing (post-route, CLOCK_PERIOD = 20 ns / 50 MHz target) | Corner | Setup WNS (ns) | Setup TNS (ns) | Hold WNS (ns) | Hold TNS (ns) | |--------|----------------|-----------------|----------------|----------------| | nom_tt_025C_1v80 | **0.0** | 0 | -0.45 | -10.5 | | nom_ss_100C_1v60 | **-9.18** | -12,474.4 | -0.17 | -0.21 | | nom_ff_n40C_1v95 | **0.0** | 0 | -0.37 | -38.6 | | max_ss_100C_1v60 | -10.45 | -15,896.8 | -0.44 | -0.87 | ### Estimated Max Frequency - **TT corner**: **50 MHz — TIMING MET** - **SS corner**: Critical path ~40 ns → **~25 MHz** (up from ~11 MHz) - **FF corner**: **50 MHz — TIMING MET** ### New Critical Path (SS corner) | Item | Value | |------|-------| | Startpoint | `u_core.col_idx[0]` (column index register) | | Endpoint | `u_core.beliefs` registers | | Slack | -9.18 ns (nom_ss) | | Data arrival time | 40.15 ns | | Description | Belief update mux path during LAYER_READ/LAYER_WRITE | The syndrome path is NO LONGER critical. The new bottleneck is the column-indexed mux/barrel-shifter path used during belief reads and writes. ### Key Observations 1. **Balanced popcount tree eliminated the syndrome bottleneck** — WNS improved from -28.98 ns to 0.0 ns at TT 2. TT and FF corners now fully meet 50 MHz timing 3. SS corner still fails (-9.18 ns) due to a different path: belief update mux indexed by col_idx 4. Hold violations are minor (-0.45 ns) and can be fixed with post-route optimization 5. 1,687 antenna violations need to be addressed (antenna repair was disabled) ## Updated Summary Table | Run | RTL | Key Change | Antenna | Status | TT Setup WNS | Max Freq (TT) | |-----|-----|------------|---------|--------|-------------|---------------| | 1 | Unpipelined | — | Heuristic | **FAILED** | — | — | | 2 | Unpipelined | — | Iterative | **COMPLETED** | -27.13 ns | ~21 MHz | | 3 | Pipelined CN | CN pipeline | Iterative | **FAILED** | — | — | | 4 | Pipelined CN | CN pipeline | None | **COMPLETED** | -28.86 ns | ~20 MHz | | 5 | + Syndrome pipeline | Serial popcount | None | **COMPLETED** | -28.98 ns | ~20 MHz | | 6 | + Balanced popcount | Adder tree | None | **COMPLETED** | **0.0 ns** | **50 MHz** | ## Run 7a: `pipelined_layer2` (Mar 9, 2026) — FAILED - **RTL**: Run 6 + LAYER_WRITE split into LAYER_WRITE_ADDR + LAYER_WRITE_DATA - **Config**: `CLOCK_PERIOD=20`, `DIODE_ON_PORTS=in`, `HEURISTIC_ANTENNA_THRESHOLD=200` - **Failure**: `GRT-0118` routing congestion — heuristic diode insertion on input ports added too many cells - **Lesson**: Any heuristic diode insertion causes GRT failure on this design ## Run 7b: `pipelined_layer3` (Mar 9, 2026) — FAILED - **RTL**: Same as 7a (LAYER_WRITE_ADDR/DATA split) - **Config**: `DIODE_ON_PORTS=none`, `RUN_HEURISTIC_DIODE_INSERTION=false` - **Failure**: Post-CTS resizer diverged — 2.5+ hours at 100% CPU, memory climbing linearly, never converging - **Lesson**: LAYER_WRITE pipeline split creates too many paths for OpenROAD resizer ## Run 7c: `pre_shift` (Mar 9, 2026) — FAILED - **RTL**: Run 6 + pre-registered H_BASE shift lookahead (`H_BASE[row_idx][col_idx+1]`) - **Config**: Same as 7b - **Failure**: `GPL-0302` placement density overflow — 150K cells at 41.3% exceeded 40% target - **Root cause**: Yosys cannot fold H_BASE constants through registers → full 256:1 write mux explosion (~2x cell count vs Run 6's 83K) - **Lesson**: Registering H_BASE shift values prevents Yosys constant folding ## Run 7d: `run6_baseline` (Mar 9, 2026) — FAILED - **RTL**: Reverted to Run 6 baseline (identical RTL) - **Config**: `DIODE_ON_PORTS=in` (inadvertently left from earlier runs), `RUN_HEURISTIC_DIODE_INSERTION=false` - **Cells**: 85,500 - **Failure**: `GRT-0118` routing congestion - **Root cause**: `DIODE_ON_PORTS=in` inserts diodes on input ports even when heuristic insertion is disabled ## Run 7e: `run6b_nodiode` (Mar 10, 2026) — FAILED - **RTL**: Run 6 baseline - **Config**: `DIODE_ON_PORTS=none`, hold margins 0.5/0.3 (from config.json), reused `run6_baseline` synthesis - **Failure**: Post-CTS resizer diverged (9+ GiB memory, 3+ hours, never converged) - **Root cause**: Reusing synthesis from a run with different config (`DIODE_ON_PORTS=in`) produces a subtly different netlist that causes PnR divergence ## Run 7f: `run6_clean` (Mar 10, 2026) — FAILED - **RTL**: Run 6 baseline, clean full run from scratch - **Config**: `DIODE_ON_PORTS=none`, hold margins 0.5/0.3 - **Cells**: 85,500 - **Hold buffers inserted**: 35,506 - **Failure**: `GRT-0118` routing congestion - **Root cause**: Higher hold slack margins (0.5/0.3 vs balanced_popcount's 0.4/0.2) caused 13K extra hold buffers (35K vs 22K), pushing routing congestion over GRT threshold ## Run 7g: `run6_fixhold` (Mar 10, 2026) — FAILED - **RTL**: Run 6 baseline, reused `run6_clean` synthesis - **Config**: `DIODE_ON_PORTS=none`, hold margins 0.4/0.2 (matching balanced_popcount) - **Failure**: Post-CTS resizer diverged (14+ GiB, 3.5+ hours) - **Root cause**: Yosys non-determinism — `run6_clean` synthesis produced a slightly different cell mix that didn't route cleanly despite identical config ## Run 7h: `run6_reuse_bp` (Mar 10, 2026) — COMPLETED (reproduces Run 6!) - **RTL**: Run 6 baseline, **reused balanced_popcount's actual synthesis netlist** - **Config**: `DIODE_ON_PORTS=none`, hold margins 0.4/0.2 - **Result**: All stages completed. DRC/LVS clean. TT timing met! - **Hold buffers**: 22,095 (identical to balanced_popcount) ### Physical Results | Metric | Result | |--------|--------| | Magic DRC | **Clean** | | KLayout DRC | **Clean** | | LVS | **Clean** (circuits match uniquely) | | Antenna violating nets | 1,687 (repair disabled) | | Antenna violating pins | 3,416 (repair disabled) | ### Area & Utilization | Metric | Value | |--------|-------| | Die area | 4,928,000 µm² (4.93 mm²) | | Instance count | 186,915 | | Instance area | 1,367,580 µm² (1.37 mm²) | | Core utilization | 28.2% | ### Timing (post-route, CLOCK_PERIOD = 20 ns / 50 MHz target) | Corner | Setup WNS (ns) | Setup TNS (ns) | Hold WNS (ns) | Hold TNS (ns) | |--------|----------------|-----------------|----------------|----------------| | nom_tt_025C_1v80 | **+3.28** | 0 | -0.45 | -10.5 | | nom_ss_100C_1v60 | **-9.18** | -12,474 | -0.17 | -0.21 | | nom_ff_n40C_1v95 | **+5.93** | 0 | -0.37 | -38.6 | | max_ss_100C_1v60 | -10.45 | -15,897 | -0.44 | -0.87 | | min_tt_025C_1v80 | +3.71 | 0 | -0.26 | -1.66 | | max_tt_025C_1v80 | +2.90 | 0 | -0.62 | -29.5 | ### Key Observations 1. **Results identical to Run 6** — confirms that the balanced_popcount synthesis netlist is the key ingredient 2. Yosys non-determinism is significant: re-synthesizing the same RTL with same config produces netlists that fail PnR 3. Hold violations (1,543 total) are all on input port paths (`wb_dat_i`, `wb_adr_i`), zero reg-to-reg — fixable with input delay constraints 4. Max slew violations (4,112) and max cap violations (655) concentrated in SS corner ## Updated Summary Table | Run | RTL | Key Change | Antenna | Status | TT Setup WNS | Max Freq (TT) | |-----|-----|------------|---------|--------|-------------|---------------| | 1 | Unpipelined | — | Heuristic | **FAILED** | — | — | | 2 | Unpipelined | — | Iterative | **COMPLETED** | -27.13 ns | ~21 MHz | | 3 | Pipelined CN | CN pipeline | Iterative | **FAILED** | — | — | | 4 | Pipelined CN | CN pipeline | None | **COMPLETED** | -28.86 ns | ~20 MHz | | 5 | + Syndrome pipeline | Serial popcount | None | **COMPLETED** | -28.98 ns | ~20 MHz | | 6 | + Balanced popcount | Adder tree | None | **COMPLETED** | **0.0 ns** | **50 MHz** | | 7a | + LAYER_WRITE split | ADDR/DATA pipeline | Heuristic | **FAILED** | — | — | | 7b | + LAYER_WRITE split | ADDR/DATA pipeline | None | **FAILED** (resizer) | — | — | | 7c | + pre_shift | H_BASE lookahead | None | **FAILED** (GPL) | — | — | | 7d | Run 6 baseline | DIODE_ON_PORTS=in | None | **FAILED** (GRT) | — | — | | 7e | Run 6 baseline | Reuse wrong synth | None | **FAILED** (resizer) | — | — | | 7f | Run 6 baseline | Hold margins 0.5/0.3 | None | **FAILED** (GRT) | — | — | | 7g | Run 6 baseline | Reuse run6_clean synth | None | **FAILED** (resizer) | — | — | | 7h | Run 6 baseline | **Reuse BP synth** | None | **COMPLETED** | **+3.28 ns** | **50 MHz** | ## Key Lessons Learned (Run 7 Series) 1. **LAYER_WRITE pipeline is not viable**: Any register between col_idx and H_BASE causes either cell explosion (Yosys can't fold constants through registers) or PnR divergence (too many paths for resizer) 2. **Heuristic diode insertion always fails**: Both `RUN_HEURISTIC_DIODE_INSERTION=true` and `DIODE_ON_PORTS=in` cause GRT-0118 congestion 3. **Hold slack margins matter**: 0.5/0.3 inserts 35K hold buffers → GRT failure. 0.4/0.2 inserts 22K → passes 4. **Yosys synthesis is non-deterministic**: Re-synthesizing identical RTL+config produces different netlists with different PnR outcomes. The balanced_popcount synthesis netlist is the only one proven to complete 5. **Config must be consistent**: Reusing synthesis from a run with different config settings causes PnR divergence 6. **Run 6's balanced_popcount synthesis netlist is the golden reference** — all future PnR runs should reuse it ## Next Steps - Address antenna violations (1,687 nets) for tapeout — try `GRT_ANTENNA_ITERS` with reused BP synthesis - Fix hold violations via input delay constraints (all are input port paths) - Consider relaxing SS target or adding pipeline stage to belief update mux for SS corner improvement - Investigate making Yosys synthesis deterministic (fixed random seed, etc.) for reproducible builds