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Bump OpenROAD: rsz rebuffering estimation-accuracy series#4347

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Bump OpenROAD: rsz rebuffering estimation-accuracy series#4347
minjukim55 wants to merge 6 commits into
The-OpenROAD-Project:masterfrom
The-OpenROAD-Project-staging:secure-rsz-buffering-boost-orfs

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Summary

Bump tools/OpenROAD to pick up the rsz rebuffering estimation-accuracy
series (upstream author Martin Povišer): rebuffer's internal delay/slew
estimate is realigned with the model repair_design / signoff STA use, plus
fixes to the buffered-net cost model (shape-factor location, slew degradation
model, wire-splitting formula, buffered-net delay methodology, junction
placement, buffer-load miscount, long-wire algorithm, zero-RC guards).

The pinned OR commit = ORFS-master's current OR pin + only the rsz series
(cherry-picked onto the same base), so ORFS CI isolates this change from OR
master drift.

Corresponding OpenROAD PR: The-OpenROAD-Project/OpenROAD#10866.

Type of change

  • Dependency update (OpenROAD submodule bump)

Impact

Rebuffering quality only. On a customer design (advanced-node PDK, 5 seeds)
the setup-WS / fmax improved consistently from CTS onward (CTS +8.98%,
GRT +7.08% mean fmax; 5/5 seeds improve at both stages). ORFS flow metric
goldens may shift for affected designs; CI will surface which, and those will
be regenerated in a follow-up commit.

Verification

  • OR side: unit tests (rsz 241/241) + flow goldens regenerated and green
    locally; No-Diffs-In-Ok-Files clean.
  • ORFS side: relying on CI to flag any metric-golden churn.

Related Issues

Upstream rsz rebuffering-accuracy series; QoR validation tracked internally
(private).

Point tools/OpenROAD at the rsz rebuffering-accuracy series (private OR
branch secure-rsz-buffering-boost-orfs = ORFS-master OR pin + the series)
so ORFS picks up the improved rebuffer delay/slew estimation.

OR base = ORFS-master's current OR pin (f5df0085) + only the rsz series,
so ORFS CI isolates this change from master drift.

Signed-off-by: Minju Kim <mkim@precisioninno.com>
…ries

Regenerate rules-base.json for the 13 CI designs whose metrics shifted
after the OpenROAD bump (Private ORFS CI build #1). The improved rebuffer
delay/slew estimation moved setup-TNS (and routing/area/buffer-count)
metrics; goldens regenerated with `make update_rules` (--failing
--tighten) from the CI run's metadata.json.

Designs: asap7/{aes,ethmac,ethmac_lvt,mock-alu}, gf180/{aes,aes-hybrid},
nangate45/{ariane133,swerv}, sky130hd/{aes,microwatt,riscv32i},
sky130hs/{jpeg,riscv32i}.

Note: swerv_wrapper/asap7 also failed CI but is NOT a golden shift -- it
SIGSEGVs in PrimaDelayCalc::simulate1 during replace_arith_modules
(delay-calc, unrelated to rebuffering); tracked separately.

Signed-off-by: Minju Kim <mkim@precisioninno.com>
@minjukim55 minjukim55 self-assigned this Jul 12, 2026

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Code Review

This pull request updates the tools/OpenROAD submodule to a newer commit and adjusts the baseline design rules (rules-base.json) across various platforms and designs (such as asap7, gf180, nangate45, sky130hd, and sky130hs) to reflect the resulting changes in physical design metrics like timing, area, and wirelength. There are no review comments, so I have no feedback to provide.

Secure CI area metrics exceeded the padded ceilings after the
rebuffering estimation-accuracy change. Regenerate with the standard
15% padding (make update_rules):
  placeopt__design__instance__area 4159 -> 4810
  finish__design__instance__area   4236 -> 4886

Signed-off-by: Minju Kim <mkim@precisioninno.com>
Signed-off-by: Minju Kim <mkim@precisioninno.com>

# Conflicts:
#	tools/OpenROAD
Pin tools/OpenROAD at the rsz rebuffering estimation-accuracy series head
(The-OpenROAD-Project/OpenROAD#10866, upstream author Martin Poviser). This
drops the earlier SparseLU-guard bump so the submodule pin resolves against
public OpenROAD for ORFS CI.

Signed-off-by: Minju Kim <mkim@precisioninno.com>
@openroad-ci openroad-ci force-pushed the secure-rsz-buffering-boost-orfs branch from 35b302d to 1cebfb9 Compare July 13, 2026 08:30
The rsz rebuffering estimation-accuracy series (OpenROAD#10866) shifts
asap7/mock-alu finish__timing__setup__tns to -20481.5. Regenerate the rule
bound to -20541.5 (period_padding, 20% of the 300ps clock period).

Signed-off-by: Minju Kim <mkim@precisioninno.com>
@minjukim55

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1 CI crash from OpenSTA - filed a issue The-OpenROAD-Project/OpenROAD#10893

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