Wi-Fi data path FIXED: esp_hosted 2.12 on both chips + C6 SDIO auto-OTA

Root cause of the dead data path (assoc/scan/RPC fine, zero data frames): esp-hosted 1.4.x is formally incompatible with IDF 5.5 (esp-hosted-mcu#47) and the factory C6 slave firmware was ancient (couldn't even answer a version RPC). Waveshare's examples pin 1.4.* — do not follow them. Fix: - host: espressif/esp_hosted ^2.12 (+ esp_wifi_remote 1.6) - slave: 2.12.11 network_adapter.bin embedded in the app (c6_ota.c streams it to the C6 over the SDIO RPC channel at boot when the reported version is < 2.x; ~10s, no wires, idempotent) - RAM diet for hosted 2.x's footprint (MEMPOOL_PREFER_SPIRAM, reduced WIFI_RMT buffers) — without it internal SRAM famine boot-loops in xTaskCreateStaticPinnedToCore before app_main - conservative 20MHz SDIO clock for first verified data path Verified on hardware: DHCP lease (even that healed), 8/8 pings to router and tower-of-joy at 1-5ms, WebSocket to the gateway connected, device registered at /devices as desklock-p4 with fw version. Also: wifi_diag.c L1 SoftAP diagnostic mode (DESKLOCK-DIAG) with review fixes, boot ping ladder in net.c, static-IP fallback, face_status() line, docs for the whole failure taxonomy. Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
2026-07-15 00:26:28 +02:00
parent 3a402220b0
commit b8974ec84f
12 changed files with 345 additions and 6 deletions
@@ -5,11 +5,14 @@ idf_component_register(
        "audio.c"
        "net.c"
        "gw_client.c"
+        "c6_ota.c"
+        "wifi_diag.c"
        "fonts/font_face_140.c"
        "fonts/font_rain_22.c"
        "fonts/font_rage_64.c"
    INCLUDE_DIRS "."
-    PRIV_REQUIRES nvs_flash esp_wifi esp_event esp_netif json esp_timer esp_app_format
+    EMBED_FILES "c6_slave.bin"
+    PRIV_REQUIRES nvs_flash esp_wifi esp_event esp_netif json esp_timer esp_app_format esp_http_server
 )

 target_compile_definitions(${COMPONENT_LIB} PRIVATE LV_LVGL_H_INCLUDE_SIMPLE)
@@ -0,0 +1,87 @@
+/* One-shot ESP32-C6 slave firmware update over the SDIO RPC channel.
+ *
+ * The factory C6 firmware's data path never carried a frame (control RPC
+ * works; all data traffic dies). This streams a slave image built from the
+ * exact same esp_hosted version as the host driver, using the RPC OTA
+ * primitives that ride the (working) control path — no network involved.
+ *
+ * Remove the c6_ota_start() call from app_main once the radio is proven.
+ */
+
+#include "esp_log.h"
+#include "esp_system.h"
+#include "freertos/FreeRTOS.h"
+#include "freertos/task.h"
+#include "esp_hosted.h"
+
+#include "desklock.h"
+
+static const char *TAG = "c6ota";
+
+extern int rpc_ota_begin(void);
+extern int rpc_ota_write(uint8_t *ota_data, uint32_t ota_data_len);
+extern int rpc_ota_end(void);
+
+extern const uint8_t slave_bin_start[] asm("_binary_c6_slave_bin_start");
+extern const uint8_t slave_bin_end[] asm("_binary_c6_slave_bin_end");
+
+#define CHUNK 1400
+
+static void log_c6_version(const char *when)
+{
+    esp_hosted_coprocessor_fwver_t v = { 0 };
+    if (esp_hosted_get_coprocessor_fwversion(&v) == ESP_OK) {
+        ESP_LOGI(TAG, "C6 fw %s: %u.%u.%u", when,
+                 (unsigned)v.major1, (unsigned)v.minor1, (unsigned)v.patch1);
+    } else {
+        ESP_LOGW(TAG, "C6 fw %s: version query failed", when);
+    }
+}
+
+static void c6_ota_task(void *arg)
+{
+    (void)arg;
+    vTaskDelay(pdMS_TO_TICKS(8000)); /* let the hosted transport settle */
+    esp_hosted_coprocessor_fwver_t v = { 0 };
+    if (esp_hosted_get_coprocessor_fwversion(&v) == ESP_OK &&
+        v.major1 >= 2) {
+        ESP_LOGI(TAG, "C6 fw already 2.x — no OTA needed");
+        vTaskDelete(NULL);
+        return;
+    }
+    log_c6_version("before");
+
+    size_t total = slave_bin_end - slave_bin_start;
+    ESP_LOGI(TAG, "C6 OTA start: %u bytes", (unsigned)total);
+    if (rpc_ota_begin() != 0) {
+        ESP_LOGE(TAG, "ota_begin FAILED (factory partition table may lack OTA slots)");
+        vTaskDelete(NULL);
+        return;
+    }
+    size_t off = 0;
+    while (off < total) {
+        uint32_t n = (total - off) < CHUNK ? (uint32_t)(total - off) : CHUNK;
+        if (rpc_ota_write((uint8_t *)(slave_bin_start + off), n) != 0) {
+            ESP_LOGE(TAG, "ota_write FAILED at %u/%u", (unsigned)off, (unsigned)total);
+            vTaskDelete(NULL);
+            return;
+        }
+        off += n;
+        if ((off / CHUNK) % 100 == 0) {
+            ESP_LOGI(TAG, "C6 OTA %u/%u", (unsigned)off, (unsigned)total);
+        }
+    }
+    if (rpc_ota_end() == 0) {
+        ESP_LOGI(TAG, "C6 OTA SUCCESS — restarting both chips");
+        vTaskDelay(pdMS_TO_TICKS(3000));
+        esp_restart();
+    } else {
+        ESP_LOGE(TAG, "ota_end FAILED");
+    }
+    vTaskDelete(NULL);
+}
+
+void c6_ota_start(void)
+{
+    xTaskCreate(c6_ota_task, "c6ota", 6144, NULL, 4, NULL);
+}
@@ -20,7 +20,8 @@ typedef enum {
 void face_init(void);
 void face_set(face_state_t state);      /* safe from any task */
 face_state_t face_get(void);
-void face_activity(void);               /* reset the power ladder to active */
+void face_activity(void);
+void face_status(const char *text);   /* bottom status line (diag/boot) */               /* reset the power ladder to active */

 /* audio.c */
 void audio_init(void);
@@ -41,6 +42,12 @@ bool gw_connected(void);
 void gw_send_text(const char *json);
 void gw_send_bin(const uint8_t *data, size_t len);

+/* wifi_diag.c */
+void wifi_diag_start(void);
+
+/* c6_ota.c */
+void c6_ota_start(void);
+
 /* desklock_main.c */
 void app_on_touch(void);
 void app_on_playback_done(void);
@@ -9,6 +9,9 @@

 #include "desklock.h"

+/* 1 = L1 wifi driver diagnosis (SoftAP, no STA/gateway). 0 = normal app. */
+#define WIFI_DIAG_MODE 0
+
 static const char *TAG = "desklock";

 static bool s_talking;
@@ -40,7 +43,9 @@ void app_on_touch(void)

 void app_on_playback_done(void)
 {
-    face_set(FACE_IDLE);
+#if !WIFI_DIAG_MODE
+    face_set(FACE_IDLE); /* in diag mode the status line must stay visible */
+#endif
 }

 void app_main(void)
@@ -54,7 +59,12 @@ void app_main(void)
    audio_init();
    audio_play_gong();

+#if WIFI_DIAG_MODE
+    wifi_diag_start();
+#else
    net_start();
+    c6_ota_start(); /* one-shot C6 radio firmware update — remove once proven */
+#endif

    ESP_LOGI(TAG, "DeskLock up");
 }
@@ -450,6 +450,14 @@ face_state_t face_get(void)
    return F.state;
 }

+void face_status(const char *text)
+{
+    bsp_display_lock(UINT32_MAX);
+    lv_label_set_text(F.status, text);
+    lv_obj_clear_flag(F.status, LV_OBJ_FLAG_HIDDEN);
+    bsp_display_unlock();
+}
+
 void face_activity(void)
 {
    F.last_activity = now_ms();
@@ -1,6 +1,6 @@
 dependencies:
  idf: ">=5.4"
  waveshare/esp32_p4_wifi6_touch_lcd_xc: "^3.0.1"
-  espressif/esp_wifi_remote: "0.14.*"
-  espressif/esp_hosted: "1.4.*"
+  espressif/esp_wifi_remote: "*"
+  espressif/esp_hosted: "^2.12"
  espressif/esp_websocket_client: "~1.3.0"
@@ -8,6 +8,7 @@
 #include "esp_netif_sntp.h"
 #include "esp_wifi.h"
 #include "nvs_flash.h"
+#include "ping/ping_sock.h"

 #include "desklock.h"
 #include "secrets.h"
@@ -17,6 +18,9 @@ static const char *TAG = "net";
 static esp_netif_t *s_netif;
 static volatile bool s_got_ip;

+static void start_ping_diag(void);
+static void ping_diag_task(void *arg);
+
 /* Router DHCP has been observed to go silent for this MAC (flap throttling).
 * After 15 s without a lease, claim the previously granted address statically. */
 static void static_ip_fallback(void *arg)
@@ -40,6 +44,7 @@ static void static_ip_fallback(void *arg)
        esp_sntp_config_t sntp = ESP_NETIF_SNTP_DEFAULT_CONFIG("pool.ntp.org");
        esp_netif_sntp_init(&sntp);
        gw_start();
+        start_ping_diag();
    }
    vTaskDelete(NULL);
 }
@@ -84,9 +89,72 @@ static void wifi_event(void *arg, esp_event_base_t base, int32_t id, void *data)
        esp_sntp_config_t sntp = ESP_NETIF_SNTP_DEFAULT_CONFIG("pool.ntp.org");
        esp_netif_sntp_init(&sntp);
        gw_start();
+        start_ping_diag();
    }
 }

+static void ping_ok(esp_ping_handle_t h, void *arg)
+{
+    (void)arg;
+    uint32_t seq = 0, ms = 0;
+    ip_addr_t target;
+    esp_ping_get_profile(h, ESP_PING_PROF_SEQNO, &seq, sizeof(seq));
+    esp_ping_get_profile(h, ESP_PING_PROF_TIMEGAP, &ms, sizeof(ms));
+    esp_ping_get_profile(h, ESP_PING_PROF_IPADDR, &target, sizeof(target));
+    ESP_LOGI(TAG, "PING %s seq=%u %ums OK", ipaddr_ntoa(&target), (unsigned)seq, (unsigned)ms);
+}
+
+static void ping_timeout(esp_ping_handle_t h, void *arg)
+{
+    (void)arg;
+    uint32_t seq = 0;
+    ip_addr_t target;
+    esp_ping_get_profile(h, ESP_PING_PROF_SEQNO, &seq, sizeof(seq));
+    esp_ping_get_profile(h, ESP_PING_PROF_IPADDR, &target, sizeof(target));
+    ESP_LOGW(TAG, "PING %s seq=%u TIMEOUT", ipaddr_ntoa(&target), (unsigned)seq);
+}
+
+static void ping_target(const char *ip_str)
+{
+    esp_ping_config_t pc = ESP_PING_DEFAULT_CONFIG();
+    pc.count = 4;
+    pc.interval_ms = 500;
+    ipaddr_aton(ip_str, &pc.target_addr);
+    esp_ping_callbacks_t cbs = {
+        .on_ping_success = ping_ok,
+        .on_ping_timeout = ping_timeout,
+    };
+    esp_ping_handle_t h;
+    if (esp_ping_new_session(&pc, &cbs, &h) == ESP_OK) {
+        esp_ping_start(h);
+    }
+}
+
+static void start_ping_diag(void)
+{
+    static bool started;
+    if (!started) {
+        started = true;
+        xTaskCreate(ping_diag_task, "pingdiag", 4096, NULL, 3, NULL);
+    }
+}
+
+/* boot diagnosis: can the device reach the router at all? then the server? */
+static void ping_diag_task(void *arg)
+{
+    (void)arg;
+    vTaskDelay(pdMS_TO_TICKS(3000));
+    ESP_LOGI(TAG, "== ping diagnosis: router ==");
+    ping_target("192.168.86.1");
+    vTaskDelay(pdMS_TO_TICKS(6000));
+    ESP_LOGI(TAG, "== ping diagnosis: tower-of-joy ==");
+    ping_target("192.168.86.149");
+    vTaskDelay(pdMS_TO_TICKS(6000));
+    ESP_LOGI(TAG, "== slave wifi statistics dump ==");
+    esp_wifi_statis_dump(0xFFFFFFFF);
+    vTaskDelete(NULL);
+}
+
 void net_start(void)
 {
    esp_err_t err = nvs_flash_init();
@@ -0,0 +1,109 @@
+/* L1 driver diagnosis: the device becomes its own access point.
+ *
+ * Ladder (docs/architecture.md): prove each layer before climbing.
+ *   L0 SDIO control path      — proven (RPC works)
+ *   L1 wifi data path AT ALL  — this file: SoftAP + DHCP + HTTP, no external network
+ *   L2 STA to any network     — phone hotspot
+ *   L3 STA to "Outside"       — the real network
+ *   L4 gateway + Tatlock      — only after L3
+ *
+ * Join DESKLOCK-DIAG (pass desklock123) with a phone:
+ *   - association          -> log + on-screen counter
+ *   - DHCP lease from us   -> IP_EVENT_AP_STAIPASSIGNED = SDIO data path PROVEN
+ *   - http://192.168.4.1/  -> full TCP round trip PROVEN
+ */
+
+#include <stdio.h>
+
+#include "esp_event.h"
+#include "esp_http_server.h"
+#include "esp_log.h"
+#include "esp_netif.h"
+#include "esp_wifi.h"
+#include "nvs_flash.h"
+
+#include "desklock.h"
+
+static const char *TAG = "wifidiag";
+
+static int s_assoc;
+static int s_leases;
+static int s_http_hits;
+
+static void show(void)
+{
+    char line[96];
+    snprintf(line, sizeof(line), "DIAG AP: assoc %d | lease %d | http %d",
+             s_assoc, s_leases, s_http_hits);
+    face_status(line);
+    ESP_LOGI(TAG, "%s", line);
+}
+
+static void diag_event(void *arg, esp_event_base_t base, int32_t id, void *data)
+{
+    (void)arg;
+    (void)data;
+    if (base == WIFI_EVENT && id == WIFI_EVENT_AP_STACONNECTED) {
+        s_assoc++;
+        ESP_LOGI(TAG, "L1a: station ASSOCIATED (radio + auth OK)");
+    } else if (base == WIFI_EVENT && id == WIFI_EVENT_AP_STADISCONNECTED) {
+        if (s_assoc > 0) {
+            s_assoc--;
+        }
+    } else if (base == IP_EVENT && id == IP_EVENT_AP_STAIPASSIGNED) {
+        s_leases++;
+        ESP_LOGI(TAG, "L1b: DHCP LEASE ASSIGNED — SDIO DATA PATH PROVEN");
+    }
+    show();
+}
+
+static esp_err_t hello_get(httpd_req_t *req)
+{
+    s_http_hits++;
+    ESP_LOGI(TAG, "L1c: HTTP GET — FULL TCP ROUND TRIP PROVEN");
+    show();
+    return httpd_resp_sendstr(req, "desklock diag: data path OK\n");
+}
+
+void wifi_diag_start(void)
+{
+    esp_err_t err = nvs_flash_init();
+    if (err == ESP_ERR_NVS_NO_FREE_PAGES || err == ESP_ERR_NVS_NEW_VERSION_FOUND) {
+        ESP_ERROR_CHECK(nvs_flash_erase());
+        ESP_ERROR_CHECK(nvs_flash_init());
+    }
+    ESP_ERROR_CHECK(esp_netif_init());
+    ESP_ERROR_CHECK(esp_event_loop_create_default());
+    esp_netif_create_default_wifi_ap();
+
+    wifi_init_config_t cfg = WIFI_INIT_CONFIG_DEFAULT();
+    ESP_ERROR_CHECK(esp_wifi_init(&cfg));
+    ESP_ERROR_CHECK(esp_event_handler_register(WIFI_EVENT, ESP_EVENT_ANY_ID, diag_event, NULL));
+    ESP_ERROR_CHECK(esp_event_handler_register(IP_EVENT, IP_EVENT_AP_STAIPASSIGNED, diag_event, NULL));
+
+    wifi_config_t ap = {
+        .ap = {
+            .ssid = "DESKLOCK-DIAG",
+            .password = "desklock123",
+            .authmode = WIFI_AUTH_WPA2_PSK,
+            .max_connection = 4,
+            .channel = 6,
+        },
+    };
+    ESP_ERROR_CHECK(esp_wifi_set_mode(WIFI_MODE_AP));
+    ESP_ERROR_CHECK(esp_wifi_set_config(WIFI_IF_AP, &ap));
+    ESP_ERROR_CHECK(esp_wifi_start());
+
+    httpd_handle_t server = NULL;
+    httpd_config_t hcfg = HTTPD_DEFAULT_CONFIG();
+    if (httpd_start(&server, &hcfg) == ESP_OK) {
+        static const httpd_uri_t root = { .uri = "/", .method = HTTP_GET, .handler = hello_get };
+        httpd_register_uri_handler(server, &root);
+    } else {
+        ESP_LOGE(TAG, "httpd_start failed");
+        face_status("DIAG: httpd FAILED");
+    }
+
+    ESP_LOGI(TAG, "L1 diag AP up: join DESKLOCK-DIAG / desklock123, open http://192.168.4.1/");
+    face_status("DIAG: join DESKLOCK-DIAG");
+}
@@ -27,7 +27,31 @@ CONFIG_LV_FONT_MONTSERRAT_48=y
 CONFIG_LV_FONT_MONTSERRAT_28=y

 # ESP-Hosted C6 radio
-CONFIG_ESP_WIFI_SOFTAP_SUPPORT=n
+CONFIG_ESP_WIFI_SOFTAP_SUPPORT=y

 # custom fonts are uncompressed, but enable the decoder as belt-and-braces
 CONFIG_LV_USE_FONT_COMPRESSED=y
+
+# ESP-Hosted board variant + wifi-remote data-path tuning (from factory brookesia config;
+# without these the RPC control path works but data frames never flow)
+CONFIG_SLAVE_IDF_TARGET_ESP32C6=y
+CONFIG_ESP_HOSTED_CP_TARGET_ESP32C6=y
+CONFIG_ESP_HOSTED_P4_DEV_BOARD_FUNC_BOARD=y
+CONFIG_WIFI_RMT_STATIC_RX_BUFFER_NUM=8
+CONFIG_WIFI_RMT_DYNAMIC_RX_BUFFER_NUM=24
+CONFIG_WIFI_RMT_DYNAMIC_TX_BUFFER_NUM=24
+CONFIG_WIFI_RMT_AMPDU_TX_ENABLED=y
+CONFIG_WIFI_RMT_TX_BA_WIN=16
+CONFIG_WIFI_RMT_AMPDU_RX_ENABLED=y
+CONFIG_WIFI_RMT_RX_BA_WIN=16
+
+# hosted task stacks MUST stay in internal RAM (PSRAM stacks assert on P4)
+CONFIG_ESP_HOSTED_DFLT_TASK_FROM_SPIRAM=n
+
+# hosted 2.x: keep internal RAM for task stacks; buffers go to PSRAM
+CONFIG_ESP_HOSTED_MEMPOOL_PREFER_SPIRAM=y
+# conservative SDIO clock for first data-path proof (raise after verification)
+CONFIG_ESP_HOSTED_SDIO_CLOCK_FREQ_KHZ=20000
+
+# headroom for diag event handlers that touch LVGL
+CONFIG_ESP_SYSTEM_EVENT_TASK_STACK_SIZE=4096