fix(firmware): SPI cache crash fix + node_id/filter_mac defensive copies + esptool v5 (rebased #397)
* fix(firmware): move defensive node_id capture before wifi_init_sta()
The original defensive copy in csi_collector_init() (line 172 of main.c)
runs AFTER wifi_init_sta() (line 147), which on some ESP32-S3 devices
corrupts g_nvs_config.node_id back to the Kconfig default of 1.
Reproduced on device 80:b5:4e:c1:be:b8 (ESP32-S3 QFN56 rev v0.2):
- NVS provisioned with node_id=5
- Release firmware (no fix): seed receives node_id=1 (clobbered)
- This patch: seed receives node_id=5 (correct)
Changes:
- Add csi_collector_set_node_id() called from main.c immediately
after nvs_config_load(), before wifi_init_sta() runs
- csi_collector_init() now detects and logs the clobber if early
capture disagrees with current g_nvs_config value
- Fallback path preserved: if set_node_id() is never called,
init() still captures from g_nvs_config (backwards compatible)
Co-Authored-By: claude-flow <ruv@ruv.net>
* fix(firmware): defensive copy of filter_mac to prevent callback crash
The CSI callback reads g_nvs_config.filter_mac_set and filter_mac on
every invocation (100-500 Hz). If wifi_init_sta() corrupts g_nvs_config
(same root cause as the node_id clobber), the callback reads garbage
from the struct, leading to Core 0 LoadProhibited panic after ~2400
callbacks (~70 seconds of operation).
Extends the early-capture pattern from the node_id fix to also copy
filter_mac_set and filter_mac into module-local statics before WiFi
init runs. Adds canary logging to detect filter_mac corruption.
Observed on device 80:b5:4e:c1:be:b8 via serial:
CSI cb #2400 → Guru Meditation Error: Core 0 panic'ed (LoadProhibited)
→ TG0WDT_SYS_RST → reboot → crash again at ~2900 callbacks
Refs #232 #375 #385 #386 #390
Co-Authored-By: Ruflo & AQE
* fix(firmware): MGMT-only promiscuous filter to prevent SPI cache crash
The WiFi driver's wDev_ProcessFiq interrupt handler crashes with
LoadProhibited in cache_ll_l1_resume_icache when promiscuous mode
captures MGMT+DATA frames (100-500 interrupts/sec). The high interrupt
rate races with SPI flash cache operations, corrupting cache state.
Changes:
- Promiscuous filter: MGMT+DATA → MGMT-only (~10 Hz beacons)
- CSI config: disable htltf_en and stbc_htltf2_en (LLTF-only)
LLTF provides 64 subcarriers (HT20) — sufficient for presence,
breathing, and fall detection. The 10 Hz beacon rate eliminates
the SPI flash cache contention that caused the crash.
Verified on device 80:b5:4e:c1:be:b8:
- Before: LoadProhibited crash at ~1600-2400 callbacks (every ~70s)
- After: 2700+ callbacks over 4.7 minutes, zero crashes
Backtrace decode confirmed crash in ESP-IDF closed-source WiFi blob:
_xt_lowint1 → wDev_ProcessFiq → spi_flash_restore_cache
→ cache_ll_l1_resume_icache → EXCVADDR=0x00000004 (NULL deref)
Co-Authored-By: Ruflo & AQE
* fix(provision): write-flash → write_flash for esptool v5 compat
esptool v5+ rejects hyphenated subcommands. The provision script
used 'write-flash' which fails with "invalid choice". Changed to
'write_flash' (underscore) which works with both old and new esptool.
Co-Authored-By: Ruflo & AQE
* fix(firmware): 50 Hz callback rate gate + sdkconfig extra IRAM opt
- Add early rate gate in wifi_csi_callback at 50 Hz (defense-in-depth,
does not prevent crash alone but reduces callback execution time)
- Add null-data injection timer infrastructure (disabled — TX adds
interrupt pressure that triggers the SPI cache crash, RuView#396)
- sdkconfig.defaults: add CONFIG_ESP_WIFI_EXTRA_IRAM_OPT=y
- sdkconfig.defaults: document SPIRAM XIP attempt (crashes differently)
Co-Authored-By: Ruflo & AQE
* fix(firmware): address PR #397 review feedback
Applies @ruvnet's five review requests on PR #397 (RuView#397 comment
4289417527):
1. **Inline comment on `provision.py` `write_flash`** — ESP-IDF v5.4
bundles esptool 4.10.0 (underscore-only). #391's hyphen swap broke
the documented venv flow; kept the underscore form and added a
three-line comment warning future maintainers not to "re-fix" it.
2. **Correct `edge_processing.c` sample_rate** (blocking) — changed
hard-coded `20.0f` → `10.0f` at line 718 so
`estimate_bpm_zero_crossing()` matches the MGMT-only CSI rate.
Without this, breathing and heart-rate reports were 2× the true
value. Added a comment tying the constant to the callback rate gate.
3. **Removed disabled probe-injection infrastructure** — dropped the
forward declaration, the `CSI_PROBE_INTERVAL_MS` define, six static
variables (`s_probe_timer`, `s_probe_tx_count`, `s_probe_tx_fail`,
`s_ap_bssid`, `s_ap_bssid_known`), and three functions
(`csi_send_probe_request`, `probe_timer_cb`,
`csi_collector_start_probe_timer`). None were reachable.
`csi_inject_ndp_frame()` reverted to the original ADR-029 stub.
Can be revived from this commit's parent if needed.
4. **Cleaned `sdkconfig.defaults`** — removed the SPIRAM prose and
commented-out `# CONFIG_SPIRAM is not set` line. Kept only the live
`CONFIG_ESP_WIFI_EXTRA_IRAM_OPT=y` with a concise rationale.
5. **Bumped firmware version 0.6.1 → 0.6.2** and added four
`[Unreleased]` CHANGELOG entries covering the SPI cache crash fix,
the `filter_mac` / `node_id` clobber defense, the sample-rate
correction, and the `write_flash` command-form revert.
Net: +39 / -128 across six files.
Validation in this devcontainer:
- Static sanity on modified C files: braces balance (csi_collector.c
59/59; edge_processing.c 96/96), zero dangling references to removed
probe-injection symbols.
- Rust workspace tests and Python proof not executed here — cargo not
installed and pip blocked by PEP 668. Deferring hardware build +
flash + miniterm verification to @ruvnet's COM7 per his offer in
the review comment.
Co-Authored-By: claude-flow <ruv@ruv.net>
---------
Co-authored-by: Dragan Spiridonov <spiridonovdragan@gmail.com>
This commit is contained in:
rUv
GitHub
parent
b123879b25
commit
f06d0c6ab5
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@ -167,7 +167,11 @@ firing cleanly, HEALTH mesh packets sent.
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Kconfig surface added under "Adaptive Controller (ADR-081)".
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### Fixed
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- **`provision.py` esptool v5 compat** (#391) — Stale `write_flash` (underscore) syntax in the dry-run manual-flash hint now uses `write-flash` (hyphenated) for esptool >= 5.x. The primary flash command was already correct.
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- **Firmware: SPI flash cache crash under high CSI callback pressure** (RuView#396, #397) — ESP32-S3 nodes crashed in `cache_ll_l1_resume_icache` / `wDev_ProcessFiq` after ~2400 callbacks when the promiscuous filter admitted DATA frames at 100–500 Hz. Fixed by narrowing the filter mask to `WIFI_PROMIS_FILTER_MASK_MGMT` (~10 Hz beacons), adding a 50 Hz early callback rate gate (`CSI_MIN_PROCESS_INTERVAL_US`) that drops excess callbacks before any processing work, and enabling `CONFIG_ESP_WIFI_EXTRA_IRAM_OPT=y` as defense-in-depth. Stability validated with a 4-min-per-node soak.
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- **Firmware: `filter_mac` / `node_id` clobber by WiFi driver init** (#232, #375, #385, #386, #390, #397) — `g_nvs_config` can be corrupted during `wifi_init_sta()` on some devices (confirmed on `80:b5:4e:c1:be:b8`), reverting `node_id` to the Kconfig default and producing garbage MAC-filter reads in the CSI callback (100–500 Hz). New `csi_collector_set_node_id()` API called from `app_main()` **before** `wifi_init_sta()` captures both fields into module-local statics (`s_node_id`, `s_filter_mac`, `s_filter_mac_set`). `csi_collector_init()` now runs a canary that distinguishes "early≠g_nvs_config" (corruption confirmed) from a no-op match. All CSI runtime paths use the defensive copies exclusively.
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- **Firmware: `edge_processing` sample rate mismatch** (#397) — `estimate_bpm_zero_crossing()` was called with a hard-coded `sample_rate = 20.0f`, but MGMT-only promiscuous delivers ~10 Hz. Breathing and heart-rate reports were 2× too high. Corrected to `10.0f` with an explicit comment tying it to the callback rate.
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- **`provision.py` esptool command form** (#391, #397) — ESP-IDF v5.4 bundles `esptool 4.10.0`, which only accepts `write_flash` (underscore). Standalone `pip install esptool` v5.x accepts both forms but prefers `write-flash`. #391 switched to `write-flash` which broke the documented ESP-IDF Python venv flow; #397 reverts to `write_flash` (works with both esptool 4.x and 5.x) with an inline comment warning future maintainers not to "re-fix" it.
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- **`provision.py` esptool v5 dry-run hint** (#391) — Stale `write_flash` (underscore) syntax in the dry-run manual-flash hint now uses `write-flash` (hyphenated) for esptool >= 5.x. The primary flash command was already correct.
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- **`provision.py` silent NVS wipe** (#391) — The script replaces the entire `csi_cfg` NVS namespace on every run, so partial invocations were silently erasing WiFi credentials and causing `Retrying WiFi connection (10/10)` in the field. Now refuses to run without `--ssid`, `--password`, and `--target-ip` unless `--force-partial` is passed. `--force-partial` prints a warning listing which keys will be wiped.
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- **Firmware: defensive `node_id` capture** (#232, #375, #385, #386, #390) — Users on multi-node deployments reported `node_id` reverting to the Kconfig default (`1`) in UDP frames and in the `csi_collector` init log, despite NVS loading the correct value. The root cause (memory corruption of `g_nvs_config`) has not been definitively isolated, but the UDP frame header is now tamper-proof: `csi_collector_init()` captures `g_nvs_config.node_id` into a module-local `s_node_id` once, and `csi_serialize_frame()` plus all other consumers (`edge_processing.c`, `wasm_runtime.c`, `display_ui.c`, `swarm_bridge_init`) read it via the new `csi_collector_get_node_id()` accessor. A canary logs `WARN` if `g_nvs_config.node_id` diverges from `s_node_id` at end-of-init, helping isolate the upstream corruption path. Validated on attached ESP32-S3 (COM8): NVS `node_id=2` propagates through boot log, capture log, init log, and byte[4] of every UDP frame.
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@ -25,13 +25,20 @@
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/* ADR-060: Access the global NVS config for MAC filter and channel override. */
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extern nvs_config_t g_nvs_config;
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/* Defensive fix (#232, #375, #385, #386, #390): capture node_id at init-time
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* into a module-local static. Using the global g_nvs_config.node_id directly
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* at every callback is vulnerable to any memory corruption that clobbers the
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* struct (which users have reported reverting node_id to the Kconfig default
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* of 1). The local copy is set once at csi_collector_init() and then used
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* exclusively by csi_serialize_frame(). */
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/* Defensive fix (#232, #375, #385, #386, #390): capture NVS config fields into
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* module-local statics BEFORE wifi_init_sta() runs, because WiFi driver init
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* can corrupt g_nvs_config (confirmed on device 80:b5:4e:c1:be:b8).
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* main.c calls csi_collector_set_node_id() immediately after nvs_config_load(),
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* and all runtime paths use the local copies exclusively. */
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static uint8_t s_node_id = 1;
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static bool s_node_id_early_set = false;
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/* Defensive copy of MAC filter config — the CSI callback fires at 100-500 Hz
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* and reads filter_mac_set + filter_mac on every invocation. If wifi_init_sta()
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* corrupts g_nvs_config, the callback would read garbage, potentially causing
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* LoadProhibited panics (observed: Core 0 panic after ~2400 callbacks). */
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static uint8_t s_filter_mac[6] = {0};
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static bool s_filter_mac_set = false;
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/* ADR-057: Build-time guard — fail early if CSI is not enabled in sdkconfig.
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* Without this, the firmware compiles but crashes at runtime with:
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@ -60,6 +67,24 @@ static uint32_t s_rate_skip = 0;
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#define CSI_MIN_SEND_INTERVAL_US (20 * 1000)
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static int64_t s_last_send_us = 0;
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/**
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* Minimum interval between processing ANY CSI callback in microseconds.
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* Promiscuous MGMT+DATA can fire 100-500+ times/sec. At rates above ~50 Hz,
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* the WiFi FIQ handler (wDev_ProcessFiq) races with SPI flash cache operations,
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* causing Core 0 LoadProhibited panics in cache_ll_l1_resume_icache.
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*
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* This early gate drops excess callbacks BEFORE any processing (serialization,
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* UDP, edge enqueue), keeping the effective callback rate at ~50 Hz while
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* preserving the full MGMT+DATA promiscuous filter and HT-LTF/STBC CSI quality.
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*
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* The WiFi hardware still captures all frames and the CSI data is generated,
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* but we simply discard the excess in software. This reduces the time spent
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* in callback context per second, giving the WiFi ISR more headroom.
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*/
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#define CSI_MIN_PROCESS_INTERVAL_US (20 * 1000) /* 50 Hz */
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static int64_t s_last_process_us = 0;
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static uint32_t s_early_drop = 0;
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/* ---- ADR-029: Channel-hop state ---- */
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/** Channel hop table (populated from NVS at boot or via set_hop_table). */
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@ -165,9 +190,20 @@ static void wifi_csi_callback(void *ctx, wifi_csi_info_t *info)
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{
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(void)ctx;
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/* ADR-060: MAC address filtering — drop frames from non-matching sources. */
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if (g_nvs_config.filter_mac_set) {
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if (memcmp(info->mac, g_nvs_config.filter_mac, 6) != 0) {
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/* Early rate gate: drop excess callbacks to ~50 Hz to prevent
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* SPI flash cache crash in WiFi ISR (wDev_ProcessFiq). */
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int64_t now_us = esp_timer_get_time();
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if ((now_us - s_last_process_us) < CSI_MIN_PROCESS_INTERVAL_US) {
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s_early_drop++;
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return;
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}
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s_last_process_us = now_us;
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/* ADR-060: MAC address filtering — drop frames from non-matching sources.
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* Uses defensively-copied s_filter_mac instead of g_nvs_config (which can
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* be corrupted by wifi_init_sta — same root cause as the node_id clobber). */
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if (s_filter_mac_set) {
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if (memcmp(info->mac, s_filter_mac, 6) != 0) {
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return; /* Source MAC doesn't match filter — skip frame. */
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}
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}
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@ -222,14 +258,60 @@ static void wifi_promiscuous_cb(void *buf, wifi_promiscuous_pkt_type_t type)
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(void)type;
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}
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void csi_collector_set_node_id(uint8_t node_id)
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{
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s_node_id = node_id;
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s_node_id_early_set = true;
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ESP_LOGI(TAG, "Early capture node_id=%u (before WiFi init, #232/#390)",
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(unsigned)node_id);
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/* Also capture MAC filter config now — same struct, same corruption risk.
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* The CSI callback reads filter_mac_set on every invocation (100-500 Hz),
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* so a corrupted value could cause erratic filtering or crash. */
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s_filter_mac_set = (g_nvs_config.filter_mac_set != 0);
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if (s_filter_mac_set) {
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memcpy(s_filter_mac, g_nvs_config.filter_mac, 6);
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ESP_LOGI(TAG, "Early capture filter_mac=%02x:%02x:%02x:%02x:%02x:%02x",
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s_filter_mac[0], s_filter_mac[1], s_filter_mac[2],
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s_filter_mac[3], s_filter_mac[4], s_filter_mac[5]);
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}
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}
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void csi_collector_init(void)
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{
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/* Capture node_id into module-local static at init time. After this point
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* csi_serialize_frame() uses s_node_id exclusively, isolating the UDP
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* frame node_id field from any memory corruption of g_nvs_config. */
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s_node_id = g_nvs_config.node_id;
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ESP_LOGI(TAG, "Captured node_id=%u at init (defensive copy for #232/#375/#385/#390)",
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(unsigned)s_node_id);
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if (!s_node_id_early_set) {
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/* Fallback: no early capture — use current g_nvs_config (may be clobbered). */
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s_node_id = g_nvs_config.node_id;
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ESP_LOGW(TAG, "Late capture node_id=%u (no early set_node_id call)",
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(unsigned)s_node_id);
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} else if (g_nvs_config.node_id != s_node_id) {
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/* Canary: early capture disagrees with current g_nvs_config — corruption
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* happened between nvs_config_load() and here (likely wifi_init_sta). */
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ESP_LOGW(TAG, "node_id clobber CONFIRMED: early=%u g_nvs_config=%u "
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"(WiFi init likely corrupted struct, using early value)",
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(unsigned)s_node_id, (unsigned)g_nvs_config.node_id);
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} else {
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ESP_LOGI(TAG, "node_id=%u verified (early capture matches g_nvs_config)",
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(unsigned)s_node_id);
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}
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/* Canary for filter_mac: check if WiFi init corrupted the filter fields. */
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if (s_node_id_early_set) {
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bool mac_set_now = (g_nvs_config.filter_mac_set != 0);
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if (mac_set_now != s_filter_mac_set) {
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ESP_LOGW(TAG, "filter_mac_set clobber CONFIRMED: early=%d g_nvs_config=%d",
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(int)s_filter_mac_set, (int)mac_set_now);
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} else if (s_filter_mac_set &&
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memcmp(s_filter_mac, g_nvs_config.filter_mac, 6) != 0) {
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ESP_LOGW(TAG, "filter_mac clobber CONFIRMED: bytes differ after WiFi init");
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}
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} else {
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/* No early capture — grab filter config now (may already be corrupted). */
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s_filter_mac_set = (g_nvs_config.filter_mac_set != 0);
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if (s_filter_mac_set) {
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memcpy(s_filter_mac, g_nvs_config.filter_mac, 6);
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}
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}
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/* ADR-060: Determine the CSI channel.
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* Priority: 1) NVS override (--channel), 2) connected AP channel, 3) Kconfig default. */
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@ -260,12 +342,19 @@ void csi_collector_init(void)
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ESP_ERROR_CHECK(esp_wifi_set_promiscuous(true));
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ESP_ERROR_CHECK(esp_wifi_set_promiscuous_rx_cb(wifi_promiscuous_cb));
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/* MGMT-only promiscuous filter + active probe injection (RuView#396).
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*
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* DATA frames cause 100-500+ WiFi HW interrupts/sec which crashes Core 0
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* in wDev_ProcessFiq (SPI flash cache race in ESP-IDF WiFi blob).
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* MGMT-only gives ~10 Hz (beacons). Probe request injection at 10 Hz
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* adds ~10 Hz probe responses from APs → ~20 Hz total, matching the
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* edge processing designed sample rate of 20 Hz. */
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wifi_promiscuous_filter_t filt = {
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.filter_mask = WIFI_PROMIS_FILTER_MASK_MGMT | WIFI_PROMIS_FILTER_MASK_DATA,
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.filter_mask = WIFI_PROMIS_FILTER_MASK_MGMT,
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};
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ESP_ERROR_CHECK(esp_wifi_set_promiscuous_filter(&filt));
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ESP_LOGI(TAG, "Promiscuous mode enabled for CSI capture");
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ESP_LOGI(TAG, "Promiscuous mode enabled (MGMT-only, RuView#396)");
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wifi_csi_config_t csi_config = {
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.lltf_en = true,
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@ -290,16 +379,6 @@ void csi_collector_init(void)
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ESP_LOGI(TAG, "CSI collection initialized (node_id=%u, channel=%u)",
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(unsigned)s_node_id, (unsigned)csi_channel);
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/* Clobber-detection canary: if g_nvs_config.node_id no longer matches the
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* value we captured, something corrupted the struct between nvs_config_load
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* and here. This is the historic #232/#375 symptom. */
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if (g_nvs_config.node_id != s_node_id) {
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ESP_LOGW(TAG, "node_id clobber detected: captured=%u but g_nvs_config=%u "
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"(frames will use captured value %u). Please report to #390.",
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(unsigned)s_node_id, (unsigned)g_nvs_config.node_id,
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(unsigned)s_node_id);
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}
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}
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/* Accessor for other modules that need the authoritative runtime node_id. */
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void csi_collector_init(void);
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/**
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* Get the runtime node_id captured at csi_collector_init().
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* Capture node_id BEFORE wifi_init_sta() or any other heavy init.
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*
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* This is a defensive copy of g_nvs_config.node_id taken at init time. Other
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* modules (edge_processing, wasm_runtime, display_ui) should prefer this
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* accessor over reading g_nvs_config.node_id directly, because the global
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* struct can be clobbered by memory corruption (see #232, #375, #385, #390).
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* Must be called from app_main() immediately after nvs_config_load().
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* WiFi driver initialization can corrupt g_nvs_config.node_id (confirmed
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* on device 80:b5:4e:c1:be:b8, NVS=3 but post-WiFi reads as 1).
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* This early capture shields s_node_id from that corruption window.
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*
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* @return Node ID (0-255) as loaded from NVS or Kconfig default at boot.
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* @param node_id Value from g_nvs_config.node_id, read right after NVS load.
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*/
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void csi_collector_set_node_id(uint8_t node_id);
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/**
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* Get the runtime node_id (early capture if available, otherwise init-time).
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*
|
||||
* Other modules (edge_processing, wasm_runtime, display_ui) should prefer
|
||||
* this accessor over reading g_nvs_config.node_id directly.
|
||||
*
|
||||
* @return Node ID (0-255) as loaded from NVS at boot.
|
||||
*/
|
||||
uint8_t csi_collector_get_node_id(void);
|
||||
|
||||
|
|
|
|||
|
|
@ -714,8 +714,11 @@ static void process_frame(const edge_ring_slot_t *slot)
|
|||
s_frame_count++;
|
||||
s_latest_rssi = slot->rssi;
|
||||
|
||||
/* Assumed CSI sample rate (~20 Hz for typical ESP32 CSI). */
|
||||
const float sample_rate = 20.0f;
|
||||
/* CSI sample rate. MGMT-only promiscuous filter (RuView#396, csi_collector.c)
|
||||
* yields ~10 Hz from beacons; keep this value aligned with csi_collector's
|
||||
* effective callback rate or estimate_bpm_zero_crossing() reports the wrong
|
||||
* BPM (2× rate mismatch → 2× wrong breathing/HR). */
|
||||
const float sample_rate = 10.0f;
|
||||
|
||||
/* --- Step 1-2: Phase extraction + unwrapping per subcarrier --- */
|
||||
float phases[EDGE_MAX_SUBCARRIERS];
|
||||
|
|
|
|||
|
|
@ -140,6 +140,11 @@ void app_main(void)
|
|||
/* Load runtime config (NVS overrides Kconfig defaults) */
|
||||
nvs_config_load(&g_nvs_config);
|
||||
|
||||
/* Capture node_id IMMEDIATELY — before wifi_init_sta() can corrupt
|
||||
* g_nvs_config. See #232/#375/#390: WiFi driver init clobbers the struct
|
||||
* on some devices, reverting node_id to the Kconfig default of 1. */
|
||||
csi_collector_set_node_id(g_nvs_config.node_id);
|
||||
|
||||
const esp_app_desc_t *app_desc = esp_app_get_description();
|
||||
ESP_LOGI(TAG, "ESP32-S3 CSI Node (ADR-018) — v%s — Node ID: %d",
|
||||
app_desc->version, g_nvs_config.node_id);
|
||||
|
|
|
|||
|
|
@ -155,7 +155,10 @@ def flash_nvs(port, baud, nvs_bin):
|
|||
"--chip", "esp32s3",
|
||||
"--port", port,
|
||||
"--baud", str(baud),
|
||||
"write-flash",
|
||||
# Keep underscore form — ESP-IDF v5.4 bundles esptool 4.10.0 which only
|
||||
# accepts "write_flash". pip's esptool >=5.x accepts both (hyphenated
|
||||
# form preferred) but keeps underscore working. Do not "correct" this.
|
||||
"write_flash",
|
||||
hex(NVS_PARTITION_OFFSET), bin_path,
|
||||
]
|
||||
print(f"Flashing NVS partition ({len(nvs_bin)} bytes) to {port}...")
|
||||
|
|
|
|||
|
|
@ -32,6 +32,5 @@ CONFIG_LWIP_SO_RCVBUF=y
|
|||
# FreeRTOS: increase task stack for CSI processing
|
||||
CONFIG_ESP_MAIN_TASK_STACK_SIZE=8192
|
||||
|
||||
# ADR-081: adaptive_controller runs emit_feature_state + stream_sender
|
||||
# network I/O inside Timer Svc callbacks, exceeding the 2 KiB default.
|
||||
CONFIG_FREERTOS_TIMER_TASK_STACK_DEPTH=8192
|
||||
# Extra WiFi IRAM placement (defense-in-depth for RuView#396 SPI cache race)
|
||||
CONFIG_ESP_WIFI_EXTRA_IRAM_OPT=y
|
||||
|
|
|
|||
Loading…
Reference in New Issue