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jpmschweitzerandClaude Fable 5 cb5826e02b
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Fork fix: the SDIO wedge is FIXED (esp-hosted-mcu #167)
Root cause (verified against our exact IDF tree, not the community guess):
the "258" in "sdio_write_task: Failed to send data: 258" is NOT a timeout
(that is 263). 258 = 0x102 = ESP_ERR_INVALID_ARG. On the ESP32-P4, block-
mode CMD53 writes require the SOURCE buffer to be 64-byte (cache-line)
aligned; the IDF sdmmc driver rejects a misaligned source with INVALID_ARG
BEFORE any bus activity. esp_hosts write loop then declares "Unrecoverable
host sdio state" and reboots the whole P4. The audio TX payload is not
64-aligned, so streaming mic audio wedged on the very FIRST frame (which is
exactly what we saw: listening -> instant Failed to send -> reboot).

This also explains why buffer/queue/clock/retry tuning all did nothing: the
write never reached the bus. And why our symptom was instant, not after
~100 writes (the community block-mode-desync theory) — it is the first
misaligned buffer, every time.

Fix: vendored esp_hosted 2.12.11 as an editable local component (overrides
the registry copy) and bounce a misaligned TX payload through one aligned
DMA scratch buffer in hosted_sdio_write_block (port_esp_hosted_host_sdio.c).
TX is serialized by the bus lock so a single static bounce buffer is safe;
freed in hosted_sdio_deinit. Host-only change — no C6 reflash.

VERIFIED ON HARDWARE (autonomous self-test): 40s of continuous mic-audio
upstream streaming — the traffic that previously wedged on the first frame
— ran clean, zero timeouts, zero reboots. A guarded SDIO_TX_SELFTEST harness
is kept (compiled out) for future SDIO stress testing.

Credit: root cause + patch designed via multi-agent investigation; the
precise 258=INVALID_ARG decode (correcting the upstream community timeout
assumption) came from checking our actual esp_err.h.

Co-Authored-By: Claude Fable 5 <noreply@anthropic.com>
2026-07-15 09:50:27 +02:00

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####
# Settings copied from https://github.com/espressif/esp-idf/tree/master/examples/openthread/ot_cli
####
#
# Partition Table
#
CONFIG_PARTITION_TABLE_CUSTOM=y
CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions.csv"
CONFIG_PARTITION_TABLE_FILENAME="partitions.csv"
CONFIG_PARTITION_TABLE_OFFSET=0x8000
CONFIG_PARTITION_TABLE_MD5=y
# end of Partition Table
#
# mbedTLS
#
CONFIG_MBEDTLS_SSL_PROTO_DTLS=y
CONFIG_MBEDTLS_KEY_EXCHANGE_ECJPAKE=y
CONFIG_MBEDTLS_ECJPAKE_C=y
# end of mbedTLS
#
# OpenThread
#
CONFIG_OPENTHREAD_ENABLED=y
CONFIG_OPENTHREAD_BORDER_ROUTER=n
CONFIG_OPENTHREAD_DNS64_CLIENT=y
CONFIG_OPENTHREAD_TASK_SIZE=10240
CONFIG_OPENTHREAD_CONSOLE_ENABLE=n
# end of OpenThread
#
# lwIP
#
CONFIG_LWIP_TCPIP_TASK_STACK_SIZE=4096
CONFIG_LWIP_IPV6_NUM_ADDRESSES=8
CONFIG_LWIP_MULTICAST_PING=y
CONFIG_LWIP_HOOK_IP6_SELECT_SRC_ADDR_CUSTOM=y
# end of lwIP
#
# ESP System Settings
#
CONFIG_ESP_MAIN_TASK_STACK_SIZE=6144
# end of ESP System Settings
### SW coexistence on the co-processor is on, so this option must be
### disabled on host to keep OpenThread capabilities consistent
CONFIG_OPENTHREAD_RX_ON_WHEN_IDLE=n
### enable ESP-Hosted OpenThread Support
CONFIG_ESP_HOSTED_HOST_OT_ENABLE=y