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wifi-densepose/.github/workflows/firmware-qemu.yml

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name: Firmware QEMU Tests (ADR-061)
on:
push:
paths:
- 'firmware/**'
- 'scripts/qemu-esp32s3-test.sh'
- 'scripts/validate_qemu_output.py'
- 'scripts/generate_nvs_matrix.py'
- 'scripts/qemu_swarm.py'
- 'scripts/swarm_health.py'
- 'scripts/swarm_presets/**'
- '.github/workflows/firmware-qemu.yml'
pull_request:
paths:
- 'firmware/**'
- 'scripts/qemu-esp32s3-test.sh'
- 'scripts/validate_qemu_output.py'
- 'scripts/generate_nvs_matrix.py'
- 'scripts/qemu_swarm.py'
- 'scripts/swarm_health.py'
- 'scripts/swarm_presets/**'
- '.github/workflows/firmware-qemu.yml'
env:
IDF_VERSION: "v5.4"
QEMU_REPO: "https://github.com/espressif/qemu.git"
QEMU_BRANCH: "esp-develop"
jobs:
build-qemu:
name: Build Espressif QEMU
runs-on: ubuntu-latest
steps:
- name: Cache QEMU build
id: cache-qemu
uses: actions/cache@v4
with:
path: /opt/qemu-esp32
# Include date component so cache refreshes monthly when branch updates
key: qemu-esp32s3-${{ env.QEMU_BRANCH }}-v4
restore-keys: |
qemu-esp32s3-${{ env.QEMU_BRANCH }}-
- name: Install QEMU build dependencies
if: steps.cache-qemu.outputs.cache-hit != 'true'
run: |
sudo apt-get update
sudo apt-get install -y \
git build-essential ninja-build pkg-config \
libglib2.0-dev libpixman-1-dev libslirp-dev \
python3 python3-venv
- name: Clone and build Espressif QEMU
if: steps.cache-qemu.outputs.cache-hit != 'true'
run: |
git clone --depth 1 -b "$QEMU_BRANCH" "$QEMU_REPO" /tmp/qemu-esp
cd /tmp/qemu-esp
mkdir build && cd build
../configure \
--target-list=xtensa-softmmu \
--prefix=/opt/qemu-esp32 \
--enable-slirp \
--disable-werror
ninja -j$(nproc)
ninja install
- name: Verify QEMU binary
run: |
file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
/opt/qemu-esp32/bin/qemu-system-xtensa --version
echo "QEMU binary size: $(file_size /opt/qemu-esp32/bin/qemu-system-xtensa) bytes"
- name: Upload QEMU artifact
uses: actions/upload-artifact@v4
with:
name: qemu-esp32
path: /opt/qemu-esp32/
retention-days: 7
qemu-test:
name: QEMU Test (${{ matrix.nvs_config }})
needs: build-qemu
runs-on: ubuntu-latest
container:
image: espressif/idf:v5.4
strategy:
fail-fast: false
matrix:
nvs_config:
- default
- full-adr060
- edge-tier0
- edge-tier1
- tdm-3node
- boundary-max
- boundary-min
steps:
- uses: actions/checkout@v4
- name: Download QEMU artifact
uses: actions/download-artifact@v4
with:
name: qemu-esp32
path: /opt/qemu-esp32
- name: Make QEMU executable
run: chmod +x /opt/qemu-esp32/bin/qemu-system-xtensa
- name: Verify QEMU works
run: /opt/qemu-esp32/bin/qemu-system-xtensa --version
- name: Install Python dependencies
run: pip install esptool esp-idf-nvs-partition-gen
- name: Set target ESP32-S3
working-directory: firmware/esp32-csi-node
run: |
. $IDF_PATH/export.sh
idf.py set-target esp32s3
- name: Build firmware (mock CSI mode)
working-directory: firmware/esp32-csi-node
run: |
. $IDF_PATH/export.sh
idf.py \
-D SDKCONFIG_DEFAULTS="sdkconfig.defaults;sdkconfig.qemu" \
build
- name: Generate NVS matrix
run: |
python3 scripts/generate_nvs_matrix.py \
--output-dir firmware/esp32-csi-node/build/nvs_matrix \
--only ${{ matrix.nvs_config }}
- name: Create merged flash image
working-directory: firmware/esp32-csi-node
run: |
. $IDF_PATH/export.sh
# Determine merge_bin arguments
OTA_ARGS=""
if [ -f build/ota_data_initial.bin ]; then
OTA_ARGS="0xf000 build/ota_data_initial.bin"
fi
python3 -m esptool --chip esp32s3 merge_bin \
-o build/qemu_flash.bin \
--flash_mode dio --flash_freq 80m --flash_size 8MB \
0x0 build/bootloader/bootloader.bin \
0x8000 build/partition_table/partition-table.bin \
$OTA_ARGS \
0x20000 build/esp32-csi-node.bin
file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
echo "Flash image size: $(file_size build/qemu_flash.bin) bytes"
- name: Inject NVS partition
if: matrix.nvs_config != 'default'
working-directory: firmware/esp32-csi-node
run: |
NVS_BIN="build/nvs_matrix/nvs_${{ matrix.nvs_config }}.bin"
if [ -f "$NVS_BIN" ]; then
file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
echo "Injecting NVS: $NVS_BIN ($(file_size "$NVS_BIN") bytes)"
dd if="$NVS_BIN" of=build/qemu_flash.bin \
bs=1 seek=$((0x9000)) conv=notrunc 2>/dev/null
else
echo "WARNING: NVS binary not found: $NVS_BIN"
fi
- name: Run QEMU smoke test
env:
QEMU_PATH: /opt/qemu-esp32/bin/qemu-system-xtensa
QEMU_TIMEOUT: "90"
run: |
echo "Starting QEMU (timeout: ${QEMU_TIMEOUT}s)..."
timeout "$QEMU_TIMEOUT" "$QEMU_PATH" \
-machine esp32s3 \
-nographic \
-drive file=firmware/esp32-csi-node/build/qemu_flash.bin,if=mtd,format=raw \
-serial mon:stdio \
-nic user,model=open_eth,net=10.0.2.0/24 \
-no-reboot \
2>&1 | tee firmware/esp32-csi-node/build/qemu_output.log || true
echo "QEMU finished. Log size: $(wc -l < firmware/esp32-csi-node/build/qemu_output.log) lines"
- name: Validate QEMU output
run: |
python3 scripts/validate_qemu_output.py \
firmware/esp32-csi-node/build/qemu_output.log
- name: Upload test logs
if: always()
uses: actions/upload-artifact@v4
with:
name: qemu-logs-${{ matrix.nvs_config }}
path: |
firmware/esp32-csi-node/build/qemu_output.log
firmware/esp32-csi-node/build/nvs_matrix/
retention-days: 14
fuzz-test:
name: Fuzz Testing (ADR-061 Layer 6)
runs-on: ubuntu-latest
steps:
- uses: actions/checkout@v4
- name: Install clang
run: |
sudo apt-get update
sudo apt-get install -y clang
- name: Build fuzz targets
working-directory: firmware/esp32-csi-node/test
run: make all CC=clang
- name: Run serialize fuzzer (60s)
working-directory: firmware/esp32-csi-node/test
run: make run_serialize FUZZ_DURATION=60 || echo "FUZZER_CRASH=serialize" >> "$GITHUB_ENV"
- name: Run edge enqueue fuzzer (60s)
working-directory: firmware/esp32-csi-node/test
run: make run_edge FUZZ_DURATION=60 || echo "FUZZER_CRASH=edge" >> "$GITHUB_ENV"
- name: Run NVS config fuzzer (60s)
working-directory: firmware/esp32-csi-node/test
run: make run_nvs FUZZ_DURATION=60 || echo "FUZZER_CRASH=nvs" >> "$GITHUB_ENV"
- name: Check for crashes
working-directory: firmware/esp32-csi-node/test
run: |
CRASHES=$(find . -type f \( -name "crash-*" -o -name "oom-*" -o -name "timeout-*" \) 2>/dev/null | wc -l)
echo "Crash artifacts found: $CRASHES"
if [ "$CRASHES" -gt 0 ] || [ -n "${FUZZER_CRASH:-}" ]; then
echo "::error::Fuzzer found $CRASHES crash/oom/timeout artifacts. FUZZER_CRASH=${FUZZER_CRASH:-none}"
ls -la crash-* oom-* timeout-* 2>/dev/null
exit 1
fi
- name: Upload fuzz artifacts
if: failure()
uses: actions/upload-artifact@v4
with:
name: fuzz-crashes
path: |
firmware/esp32-csi-node/test/crash-*
firmware/esp32-csi-node/test/oom-*
firmware/esp32-csi-node/test/timeout-*
retention-days: 30
nvs-matrix-validate:
name: NVS Matrix Generation
runs-on: ubuntu-latest
steps:
- uses: actions/checkout@v4
- name: Install NVS generator
run: pip install esp-idf-nvs-partition-gen
- name: Generate all 14 NVS configs
run: |
python3 scripts/generate_nvs_matrix.py \
--output-dir build/nvs_matrix
- name: Verify all binaries generated
run: |
EXPECTED=14
ACTUAL=$(find build/nvs_matrix -type f -name "nvs_*.bin" 2>/dev/null | wc -l)
echo "Generated $ACTUAL / $EXPECTED NVS binaries"
ls -la build/nvs_matrix/
if [ "$ACTUAL" -lt "$EXPECTED" ]; then
echo "::error::Only $ACTUAL of $EXPECTED NVS binaries generated"
exit 1
fi
- name: Verify binary sizes
run: |
file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
for f in build/nvs_matrix/nvs_*.bin; do
SIZE=$(file_size "$f")
if [ "$SIZE" -ne 24576 ]; then
echo "::error::$f has unexpected size $SIZE (expected 24576)"
exit 1
fi
echo " OK: $(basename $f) ($SIZE bytes)"
done
# ---------------------------------------------------------------------------
# ADR-062: QEMU Swarm Configurator Test
#
# Runs a lightweight 3-node swarm (ci_matrix preset) under QEMU to validate
# multi-node orchestration, TDM slot coordination, and swarm-level health
# assertions. Uses the pre-built QEMU binary from the build-qemu job and the
# firmware built by qemu-test.
#
# The CI runner is non-root, so TAP bridge networking is unavailable.
# The orchestrator (qemu_swarm.py) detects this and falls back to SLIRP
# user-mode networking, which is sufficient for the ci_matrix preset.
# ---------------------------------------------------------------------------
swarm-test:
name: Swarm Test (ADR-062)
needs: [build-qemu]
runs-on: ubuntu-latest
container:
image: espressif/idf:v5.4
steps:
- uses: actions/checkout@v4
- name: Download QEMU artifact
uses: actions/download-artifact@v4
with:
name: qemu-esp32
path: ${{ github.workspace }}/qemu-build
- name: Make QEMU executable
run: chmod +x ${{ github.workspace }}/qemu-build/bin/qemu-system-xtensa
- name: Install Python dependencies
run: pip install pyyaml esptool esp-idf-nvs-partition-gen
- name: Build firmware for swarm
working-directory: firmware/esp32-csi-node
run: |
. $IDF_PATH/export.sh
idf.py set-target esp32s3
idf.py -D SDKCONFIG_DEFAULTS="sdkconfig.defaults;sdkconfig.qemu" build
python3 -m esptool --chip esp32s3 merge_bin \
-o build/qemu_flash.bin \
--flash_mode dio --flash_freq 80m --flash_size 8MB \
0x0 build/bootloader/bootloader.bin \
0x8000 build/partition_table/partition-table.bin \
0x20000 build/esp32-csi-node.bin
- name: Run swarm smoke test
run: |
python3 scripts/qemu_swarm.py --preset ci_matrix \
--qemu-path ${{ github.workspace }}/qemu-build/bin/qemu-system-xtensa \
--output-dir build/swarm-results
timeout-minutes: 10
- name: Upload swarm results
if: always()
uses: actions/upload-artifact@v4
with:
name: swarm-results
path: |
build/swarm-results/
retention-days: 14
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