Characterizing Soft-Error Resiliency in Arm's Ethos-U55 Embedded Machine Learning Accelerator

As Neural Processing Units (NPU) or accelerators are increasingly deployed in a variety of applications including safety critical applications such as autonomous vehicle, and medical imaging, it is critical to understand the fault-tolerance nature of the NPUs. We present a reliability study of Arm's Ethos-U55, an important industrial-scale NPU being utilised in embedded and IoT applications. We perform large scale RTL-level fault injections to characterize Ethos-U55 against the Automotive Safety Integrity Level D (ASIL-D) resiliency standard commonly used for safety-critical applications such as autonomous vehicles. We show that, under soft errors, all four configurations of the NPU fall short of the required level of resiliency for a variety of neural networks running on the NPU. We show that it is possible to meet the ASIL-D level resiliency without resorting to conventional strategies like Dual Core Lock Step (DCLS) that has an area overhead of 100 protection, where hardware structures are selectively protected (e.g., duplicated, hardened) based on their sensitivity to soft errors and their silicon areas. To identify the optimal configuration that minimizes the area overhead while meeting the ASIL-D standard, the main challenge is the large search space associated with the time-consuming RTL simulation. To address this challenge, we present a statistical analysis tool that is validated against Arm silicon and that allows us to quickly navigate hundreds of billions of fault sites without exhaustive RTL fault injections. We show that by carefully duplicating a small fraction of the functional blocks and hardening the Flops in other blocks meets the ASIL-D safety standard while introducing an area overhead of only 38