Or use lower VT cells (they turn "on" quicker), at the expense of increased leakage power. But at these geometries, faster clock speeds is getting less feasible and you need to find increased performance in other ways.
No logic signal needs to cross the entire die in one clock cycle, there is always an alternate design. For that reason, only registers 'talking' to each other need to see a clock at the same time, and even then there is a window. Clock routing is a consideration that takes resources but it's not a problem. Realistically, a logical signal won't be going anywhere remotely near 50mm at 3GHz in 10nm, so the clock doesn't need to either.
Max die size is also limited by the vendor's tooling i.e. what their machines can literally handle. And also physical issues such as warpage. If you make a massive die and it heats up in a non-uniform manner (different bits of it get hot at different times), it expands in a non-uniform manner. This can lead to all kinds of problems.
Chips stuffed full of memory will yield better than a logic-heavy chip since large SRAMs always now include redundancy. So this too has an impact on how big you can go for a given cost. You can however get registers that are built of multiple storage elements, the output value of which is the consensus. Don't know how much these get used.
In reality its the signal speed relative to jitter, time interval errors and data setup times that complicate the design and signal integrity.
If the clock is 3GHz, the margin of error is the fraction of the time of the clock rate. You need to divide the chip into clock regions and add local cache for each core because fetching data far away is too slow.
I've always wondered why you can't generate clocks locally, but in a synchronized way. So basically like clock regions, but without having to add extra logic for data that goes between regions.
CPU Cores use a singular clock. But when cores communicate or the L3 cache communicates (cache coherency is needed if you want that mutex / spinlock to actually work), then you need some kind of communication mechanism between the CPU Cores. Those clocks are likely "locally generated", but there needs to be a translation mechanism between Bus -> Core.
With buses, you have different clocks and data moves between them. Like you said: CPU core 1 has its own clock, the bus between them has its own and different clock, and then CPU core 2 has its own clock which is yet again different. And in those cases you actually want different clocks, because you want to be able to boost CPUs independently from each other.
What I meant goes in another direction: instead of having a single powerful clock source for e.g. a CPU core, you have multiple smaller clock sources distributed throughout the core, but synchronized to each other so they run at the same frequency and phase. So data can move freely like it does today, but clock signals don't have to be distributed as far, which would hopefully make clock distribution easier and less power hungry.
It seems like such a thing should be possible, but perhaps there are good reasons why it isn't done?
1. Clocks don't use a lot of power. Think of a pendulum: there's a lot of movement but the energy constantly swings between gravitational potential energy and kinetic energy. Although there's lots of movement, the device uses very little energy. Similarly, a clock circuit (called an oscillator) barely uses any electricity: it mostly "Swings" energy back and forth between an inverter and a capacitor.
2. Distributing a clock over a long distance similarly uses very little power (!!) due to transmission line theory. You can effectively use the parasitic capacitance in wires themselves to effectively do this pendulum effect for efficient long-distance transmission of clocks. See: https://en.wikipedia.org/wiki/Transmission_line
This gif shows an animation of the pendulum effect in a longer-transmission line: https://upload.wikimedia.org/wikipedia/commons/8/89/Transmis...
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I guess things could be de-sync'd for more efficiency. But your question is kind of like "Well, can't we get rid of V-Tables in C++ to make branch-prediction more efficient??"
I mean, we can. But V-Tables / Polymorphism really doesn't take a lot of time. We only do that if the performance gain really matters.
I do have one follow-up question though: I was under the impression that clock trees contain repeaters in the form of CMOS inverters. Wouldn't those have dynamic leakage which the transmission line stuff doesn't account for?
From my understanding: yes, the CMOS inverters will certainly use power. But you can minimize the use of them through some passive techniques.
Looking into the issue more, it does seem like a naive implementation of synchronized clocks can become costly. But at the same time, I'm seeing a number of research papers suggesting that people have been applying transmission-line techniques to the clock distribution problem.
I've always assumed that it was something that was commonly done at the chip level, but apparently not. These papers were published ~2010 or so.
Power use increases quadratically with voltage. You want small transistors to keep the voltage and power use from getting out of hand. You also need to increase voltage if you want to increase clock speed.
Electric signal travels in a conductor roughly 15 cm/nsec. With 3 GHz clock speed the electric signal travels travels roughly 50 mm in one clock cycle. Largest microchips are 30 mm across. You can't double the dimensions without dealing with the signal lag. Delivering the clock signal to every part of the chip in sync is already a problem. Modern microchips use lots of extra circuitry just to deliver the clock signal properly.