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Upstream reproduction pack for the SDIO wedge (esp-hosted-mcu#167)
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Four controlled experiments characterize it: 72-byte frame times out
at CMD53 after the slave advertised credits; bus width/clock/power
save have no effect; removing dhcpc stretches MTBF ~5min -> ~13min.
Slave-side peripheral stall, upstream bug. Device self-heals in ~15s.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
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jpmschweitzer
2026-07-15 02:12:11 +02:00
co-authored by Claude Fable 5
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# SDIO wedge reproduction pack (esp-hosted-mcu #167 family)
Evidence gathered overnight 2026-07-14→15 on Waveshare ESP32-P4-WIFI6-Touch-LCD-3.4C
(ESP32-P4 host + ESP32-C6-MINI-1 slave, SDIO: CLK18 CMD19 D0-14 D1-15 D2-16 D3-17,
slave reset GPIO54, on-board routed traces). Ready to post as an upstream issue
comment when we choose to.
## Signature
```
E H_SDIO_DRV: sdio_write_task: 0: Failed to send data: 258 72 72
E H_SDIO_DRV: sdio_write_task: 1: Failed to send data: 258 72 72
E H_SDIO_DRV: Unrecoverable host sdio state
→ SW_CPU_RESET (H_TRANSPORT_RESTART_ON_FAILURE)
```
Decoded from `sdio_drv.c` `sdio_write_task`: a 72-byte frame (`len_to_send=72,
data_left=72`, i.e. keepalive-sized) fails `_h_sdio_write_block` with
`ESP_ERR_TIMEOUT` (258) on both retries — **after** `sdio_is_write_buffer_available()`
reported credits. The slave's SDIO peripheral stops ACKing CMD53 between the credit
read and the data write. Serial is completely silent for minutes before the event
(idle link, WS ping traffic only).
## Occurrence matrix (all: host IDF v5.5, matched host+slave versions)
| Config | Time to wedge |
|---|---|
| 2.12.11, 4-bit, 40 MHz, PS default, DHCP client active | ~437 s |
| 2.12.11, 1-bit, 20 MHz, PS default, DHCP active | ~297 s |
| 2.12.11, 1-bit, 10 MHz, WIFI_PS_NONE, DHCP active | ~322 s, ~297 s |
| 2.12.11, 1-bit, 10 MHz, WIFI_PS_NONE, **static IP (no dhcpc)** | **~783 s** |
- Bus width, clock (40→10 MHz), and Wi-Fi power save have **no effect**.
- Removing the DHCP client ~2.6×'d the survival time → trigger frequency correlates
with (small-packet?) TX activity, but idle WS keepalives eventually wedge it too.
- Recovery: host auto-restart works every time (~15 s to reconnected).
- 2.9.7 slave could not be tested: its image consistently rolls back on this C6
(bootloops back to the 2.12.11 OTA slot); 2.12.11↔2.12.11 is the tested pair.
- esp-hosted 1.4.x is not comparable (no data path at all on IDF 5.5, see #47).
## Current mitigation in DeskLock
- `H_TRANSPORT_RESTART_ON_FAILURE` (default) + gong silenced on SW resets → the
device self-heals invisibly except ~15 s of CONNECTING face.
- Static addressing (`192.168.86.53`) reduces wedge frequency to ~13 min MTBF.
- Full raw serial history of every wedge in `scratchpad/nightwatch.log` captures
(session artifacts), timestamps in the repo's commit trail.