UART Transmitter only functions when embedded logic analyzer is running - vhdl

Question

I have been trying to implement a UART in order to communicate between my Lattice MachXO3D board and my computer. At the moment I am attempting to implement the transmission from the FPGA.
Upon testing on the hardware, I encountered a very strange issue. If run normally, it will function for a few seconds and then it will suddenly stop functioning (The CH340 connected to my computer will report it is receiving messages containing 0x0). However, if I embed a logic analyzer onto the FPGA through the Lattice Diamond software, and I run the analyzer, it will function perfectly for an extended period of time.
Sadly, I don't have a logic analyzer, so the embedded logic analyzer is my only chance at knowing what is actually being transmitted.
These are the files related to my implementation:
baud_gen
LIBRARY IEEE;
USE IEEE.std_logic_1164.ALL;
USE IEEE.numeric_std.ALL;
-- Generates 16 ticks per bit
ENTITY baud_gen IS
GENERIC(divider: INTEGER := 13 -- 24M/115200*16
);
PORT(
clk, reset: IN STD_LOGIC;
s_tick: OUT STD_LOGIC
);
END baud_gen;
ARCHITECTURE working OF baud_gen IS
BEGIN
PROCESS(clk)
VARIABLE counter: UNSIGNED(3 DOWNTO 0) := to_unsigned(0,4);
BEGIN
IF clk'EVENT AND clk='1' THEN
IF reset='1' THEN
s_tick <= '0';
counter := to_unsigned(0,4);
ELSIF counter=to_unsigned(divider-1,4) then
s_tick <= '1';
counter:= to_unsigned(0,4);
ELSE
s_tick <= '0';
counter := counter + 1;
END IF;
END IF;
END PROCESS;
END working;
rs232_tx
LIBRARY IEEE;
USE IEEE.std_logic_1164.ALL;
USE IEEE.numeric_std.ALL;
ENTITY rs232_tx IS
PORT(clk: IN std_logic;
tx: OUT std_logic;
rst: IN std_logic;
fifo_empty: IN std_logic;
fifo_RdEn, fifo_RdClock: OUT std_logic;
fifo_data: IN STD_LOGIC_VECTOR(7 DOWNTO 0);
Q: OUT STD_LOGIC_VECTOR(1 DOWNTO 0));
END rs232_tx;
ARCHITECTURE working OF rs232_tx IS
TYPE state IS (idle,start,data);
SIGNAL tx_pulse: STD_LOGIC := '1';
SIGNAL s_tick: STD_LOGIC;
SIGNAL pr_state, nx_state: state := idle;
SIGNAL data_val: std_logic_vector(7 DOWNTO 0):=(others=>'0');
SIGNAL data_count: unsigned(2 DOWNTO 0):=to_unsigned(0,3);
BEGIN
process(s_tick, rst)
VARIABLE count: unsigned(3 DOWNTO 0):= to_unsigned(0,4);
BEGIN
IF rising_edge(s_tick) THEN
count := count + to_unsigned(1,4);
IF count = to_unsigned(15,4) THEN
tx_pulse <= '1';
ELSE
tx_pulse <='0';
END IF;
END IF;
END PROCESS;
process(tx_pulse,rst)
BEGIN
IF rising_edge(tx_pulse) THEN
IF rst='1' THEN
pr_state <= idle;
data_val <= (others=>'0');
data_count <= to_unsigned(0,3);
ELSE
pr_state <= nx_state;
CASE pr_state IS
WHEN idle =>
data_count <= to_unsigned(0,3);
WHEN data =>
data_count <= data_count + to_unsigned(1,3);
WHEN start =>
data_val <= fifo_data;
WHEN OTHERS =>
END case;
END IF;
END IF;
END process;
process(fifo_empty,rst,data_count,pr_state,data_count)
BEGIN
case pr_state is
when idle =>
Q <= ('1','1');
fifo_RdEn <= '0';
tx <= '1';
IF fifo_empty='0' AND rst='0' THEN
nx_state <= start;
ELSE
nx_state <= idle;
END IF;
WHEN start =>
Q <= ('1','0');
fifo_RdEn <= '1';
tx <= '0';
nx_state <= data;
WHEN data =>
Q <= ('0','1');
fifo_RdEn <= '0';
tx <= data_val(to_integer(data_count));
if data_count=to_unsigned(7,3) then
nx_state <= idle;
ELSE
nx_state <= data;
end if;
end case;
END process;
fifo_RdClock <= tx_pulse;
baud_gen: ENTITY work.baud_gen
PORT MAP(clk,reset=>'0',s_tick=>s_tick);
END working;
testbench
LIBRARY IEEE;
USE IEEE.std_logic_1164.ALL;
USE IEEE.numeric_std.ALL;
ENTITY rs232_tx_test IS
GENERIC(clk_period: TIME := 41666666.7 fs;
baud_period: TIME := 8680.55556 ns);
END rs232_tx_test;
ARCHITECTURE working OF rs232_tx_test IS
SIGNAL clk: STD_LOGIC := '0';
SIGNAL tx, rst, fifo_empty, fifo_RdEn, fifo_RdClock: STD_LOGIC;
SIGNAL fifo_data: STD_LOGIC_VECTOR(7 DOWNTO 0);
BEGIN
clk <= NOT clk AFTER clk_period/2;
rst <= '1', '0' AFTER 100 ns;
PROCESS
BEGIN
fifo_empty <= '1';
WAIT FOR baud_period;
fifo_empty <= '0';
WAIT FOR baud_period*16;
END PROCESS;
fifo_data <= ('1','1','0','0','1','0','1','1') WHEN fifo_RdEn='1' ELSE (others=>'0');
dut: ENTITY work.rs232_tx
PORT MAP(clk,tx,rst,fifo_empty,fifo_RdEn,fifo_RdClock,fifo_data);
END working;
EDIT
I have tested another UART design I found online # 9600 bps and it fails in the same way. It can send a constant character, in this case 'a', to a terminal on my computer, and then it suddenly stops sending anything. However, if I start listening to the soft logic analyzer I generated in Lattice Diamond, it works without a problem and does not fail.

Answer 1

This smells like a classic timing issue.
In the comments, others have explained where there are weaknesses in the code that could indirectly lead to this. I'm going to concentrate on what is occurring.
As you have stated, in simulation your code works as you expect. However, that is only half the story. To create an FPGA bit stream the build tools take your code and several other files, synthesises, and conducts Place & Route. Your timing issue occurs during P&R. This is why your simulation doesn't pick up on any errors, as I'm assuming it's an RTL (pre-place & route) simulation.
During P&R the tools lay the logic in the best way to fit the timing model of the device so all paths meet their timing requirements. The path timing requirements are derived from explicit statements in a Timing Constraints file and inferred from your code (that's why your coding style matters btw).
Once P&R is complete, the tools will put the build artefact through a static timing analyser (STA) tool and report back whether the build fails to meet the timing requirements.
This leads to two questions:
Does the build report a timing error?
Do you have a Timing Constraints file - if you're unsure, the answer is no.
The way to debug your problem is to use the Timing Report generated by Lattice Diamond to see where the failures are.
If there are no reported failures it means your timing model is wrong because of a lack of appropriate timing constraints. As a minimum, you will need to constrain all IO in the design and describe all the clocks in your design.
Here is a good document to help you out:
https://www.latticesemi.com/-/media/LatticeSemi/Documents/UserManuals/RZ/Timing_Closure_Document.ashx?document_id=45588
The reason that your design works when you use the embedded Logic Analyser is that extra logic has been placed in the design, which changes the timing model. The P&R tools lay out the design differently, and by luck have placed the design in such a way as meet the real timing requirements on it.
As I often say to my Software Engineer colleagues, software languages create a set of instructions, HDL creates a set of suggestions.