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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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CONFIG_ESP32_DEFAULT_CPU_FREQ_240=y
CONFIG_SDIO_DAT2_DISABLED=
# BT Configuration
CONFIG_BT_ENABLED=y
CONFIG_BT_CONTROLLER_ONLY=y
CONFIG_BT_BLUEDROID_ENABLED=
CONFIG_BTDM_CONTROLLER_MODE_BTDM=y
CONFIG_BTDM_CONTROLLER_HCI_MODE_VHCI=y
CONFIG_BTDM_CTRL_AUTO_LATENCY=y
CONFIG_BTDM_CONTROLLER_MODEM_SLEEP=y
CONFIG_BTDM_CTRL_MODEM_SLEEP=y
# BT over UART
#CONFIG_BTDM_CONTROLLER_HCI_MODE_UART_H4=y
#CONFIG_BTDM_CTRL_HCI_MODE_UART_H4=y
#CONFIG_BT_HCI_UART_NO=1
#CONFIG_BT_HCI_UART_BAUDRATE=921600
#CO-EX config
CONFIG_FREERTOS_UNICORE=n
CONFIG_FREERTOS_HZ=400
CONFIG_ESP32_WIFI_TASK_PINNED_TO_CORE_1=y
CONFIG_BTDM_CONTROLLER_PINNED_TO_CORE=0
CONFIG_BTDM_CTRL_PINNED_TO_CORE=0
CONFIG_BTDM_CTRL_PINNED_TO_CORE_0=y
CONFIG_ESP32_WIFI_STATIC_RX_BUFFER_NUM=16
CONFIG_ESP32_WIFI_DYNAMIC_RX_BUFFER_NUM=32
CONFIG_ESP32_WIFI_DYNAMIC_TX_BUFFER=y
CONFIG_ESP32_WIFI_DYNAMIC_TX_BUFFER_NUM=64
# OTA
CONFIG_PARTITION_TABLE_CUSTOM=y
CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions.esp32.csv"
# iram text saving
CONFIG_FREERTOS_PLACE_FUNCTIONS_INTO_FLASH=y
# for ESP-IDF v5.5, enable these settings if building for UART transport
# needed to reduce iram usage
# CONFIG_RINGBUF_PLACE_FUNCTIONS_INTO_FLASH=y
# CONFIG_RINGBUF_PLACE_ISR_FUNCTIONS_INTO_FLASH=y
# OS
CONFIG_BOOTLOADER_COMPILER_OPTIMIZATION_SIZE=y
CONFIG_BOOTLOADER_COMPILER_OPTIMIZATION_PERF=n