Putting precision to the test

An autonomous vehicle is approaching an intersection at 35mph when its lidar system detects an object ahead. The difference between accurately measuring that object’s distance at 165 feet versus 167 feet determines whether the car can smoothly brake in time. That two extra feet could mean the difference between safety and disaster.

This level of precise measurement depends on sophisticated analog technology that bridges digital processing to our physical world.

Highly precise data converters, amplifiers, voltage references and other analog integrated circuits (ICs) are designed to capture real-world signals such as temperature, humidity, voltage, current, distance and position with extraordinary accuracy. Working together on a circuit board, these analog chips provide system-level accuracy and allow digital systems to make intelligent decisions.

Before those chips can work together, however, it’s important to test and validate them for their performance and accuracy, with advanced test equipment that must be more sophisticated than the chips themselves. Automated test systems (ATEs), high-resolution oscilloscopes, digital multimeters and other tools rely on advanced semiconductors to validate next-generation electronics. If there are any mistakes, manufacturers risk costly product failures, safety issues and, most importantly, losing consumer trust.

The relentless march of precision

"The semiconductor industry is moving toward transistors with gate lengths of 1.5nm," said Karthik Vasanth, vice president of data converters and clocking at TI. "To put that in perspective, the spacing between two atoms of silicon is about 0.23nm, so that's about five times the size of atomic spacing. It's mind-boggling."

As semiconductors reach atomic levels of precision, high-resolution test equipment must become equally sophisticated. Engineers continue to design test equipment that can measure increasing bandwidth, faster signals and higher resolution with each generation.

Robert Manion has seen that evolution firsthand at National Instruments (NI), now a part of Emerson. As general manager for semiconductor solutions for Test and Measurement, his company uses TI’s precision ICs to detect performance variations that were difficult or impossible to measure a few years ago.

“From sub‑2nm process research to silicon validation, characterization and high‑volume production ATEs, NI systems are built to test the world’s most advanced semiconductors,” Robert said. “Delivering that breadth requires us to integrate exceptional data converters and precision analog components. Combined with emerging AI capabilities in our test platforms, we’re uncovering device behaviors that were simply inaccessible a few years ago — helping chipmakers accelerate learning cycles and bring each new generation of devices to market with greater confidence.”

The precision requirements

“Designers will always pick the absolute best, most reliable parts,” Karthik said. “They will not compromise on basic precision specifications.” This reality fuels ongoing innovation as TI experiences demand from both perspectives: as a chipmaker and equipment user.

For example, amplifier precision has improved dramatically. Today’s precision amplifiers can detect electrical signals 100 times more precise than what was possible just 10 years ago. “Even a simple semiconductor component such as an amplifier is changing the world by being precise and accurate,” said Prajkta Vyavahare, vice president of amplifiers at TI.

Today’s test and measurement equipment requires precision amplifiers with incredibly stable performance where deviations must stay within microvolts, as well as achieve ultra-low noise. A data converter, for instance, must be sensitive enough to detect one defective measurement among 15 million perfect ones – all while processing over 1 billion samples per second. And voltage references must provide voltage levels with virtually zero drift over time so that test equipment can stay in service longer without adjustment and help usher in a new era of precision.

Test and measurement plays an important role in enabling device progress. “Once you design and manufacture the semiconductor, you want to make sure it meets every single performance specification you built it for,” said Prajkta. “Testing not only verifies; it gives you confidence in your design.”

Those performance requirements also create a fascinating cycle with semiconductor manufacturers and equipment makers that drives the industry. “Every product with this level of precision must be tested before it ships,” Karthik said. “It’s the enabler. Test equipment must always be more precise than the product it measures, fueling continuous innovation in semiconductor design and test technology.”

The never-ending journey

This relentless pursuit of precision applies to any application requiring more accurate measurements. Electric vehicle battery systems need precision amplifiers that can accurately measure charging current and voltages to prevent dangerous failures. Artificial intelligence (AI) chips for data centers require testing to identify the smallest defects before their deployment in servers.

Semiconductor advances will continue enabling automated test equipment with enhanced AI capabilities that predict failures and make real-time decisions. Integration breakthroughs will lead to smaller, more reliable test systems, helping manufacturers improve quality, accelerate time to market, and scale production.

“In the end, success still comes down to solving real engineering problems,” Prajkta said. “You know you've achieved precision when designers of test and measurement systems tell you that it addresses their problem.”