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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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# BT Configuration
CONFIG_BT_ENABLED=y
CONFIG_BT_CONTROLLER_ONLY=y
# OTA
CONFIG_ESPTOOLPY_FLASHSIZE_4MB=y
CONFIG_PARTITION_TABLE_TWO_OTA=y
# OS
CONFIG_FREERTOS_HZ=1000
CONFIG_ESP_WIFI_NVS_ENABLED=y
CONFIG_BOOTLOADER_COMPILER_OPTIMIZATION_PERF=y
#Disable enterprise support by default
CONFIG_ESP_WIFI_ENTERPRISE_SUPPORT=n
##
## Power Management
##
#CONFIG_PM_ENABLE=y
#CONFIG_FREERTOS_USE_TICKLESS_IDLE=y
##
## BLE + Light Sleep: MANDATORY - Enable MAC BB power down
#CONFIG_ESP_PHY_MAC_BB_PD=y
## Without this: Light sleep will be disabled if BT is enabled
##
## Down digital peripherals in light sleep
#CONFIG_PM_POWER_DOWN_PERIPHERAL_IN_LIGHT_SLEEP=y
##
#
## host power save - wake up
#CONFIG_ESP_HOSTED_HOST_POWER_SAVE_ENABLED=y
#CONFIG_ESP_HOSTED_UNLOAD_BUS_DRIVER_DURING_HOST_SLEEP=y
#CONFIG_ESP_HOSTED_LIGHT_SLEEP_ENABLE=y
#CONFIG_ESP_HOSTED_LIGHT_SLEEP_PERIPHERAL_POWERDOWN=y
#CONFIG_ESP_HOSTED_LIGHT_SLEEP_MIN_FREQ_MHZ=10
## Examples
#CONFIG_ESP_HOSTED_EXTRA_EXAMPLES=y
#CONFIG_ESP_HOSTED_COPROCESSOR_EXAMPLE_LIGHT_SLEEP=y
#
#CONFIG_ESP_HOST_DEV_BOARD_P4_C5_CORE=y