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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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# 1. CPU
#--------
CONFIG_ESP_DEFAULT_CPU_FREQ_MHZ_120=y
# 2. BT Configuration
#---------------------
CONFIG_BT_ENABLED=n
CONFIG_BT_CONTROLLER_ONLY=y
CONFIG_BT_BLUEDROID_ENABLED=
CONFIG_BT_LE_SLEEP_ENABLE=y
CONFIG_ESP_HOSTED_CP_BT=n
# 3.1 BLE over SPI/SDIO
#-----------------------
CONFIG_BT_LE_HCI_INTERFACE_USE_RAM=y
# 3.2 BLE over UART
#-------------------
#UART pins, Enable below config, delete sdkconfig and rebuild
#CONFIG_BT_LE_HCI_INTERFACE_USE_UART=y
#CONFIG_BT_LE_HCI_UART_FLOWCTRL=n
#CONFIG_BT_LE_HCI_UART_TX_PIN=5
#CONFIG_BT_LE_HCI_UART_RX_PIN=18
# 4. Partition Table
#--------------------
CONFIG_PARTITION_TABLE_CUSTOM=y
CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions.esp32c2.csv"
# 5. Mempool
#------------
CONFIG_ESP_CACHE_MALLOC=y
# 7. Transport config
#---------------------
# CONFIG_ESP_SDIO_NSEND_PSAMPLE=y
# CONFIG_ESP_SDIO_DEFAULT_SPEED=y
# CONFIG_ESP_SDIO_STREAMING_MODE=n
# 8. Wifi config
#----------------
CONFIG_WIFI_CMD_BASIC_ONLY=y
CONFIG_ESP_WIFI_STATIC_RX_BUFFER_NUM=8
CONFIG_ESP_WIFI_DYNAMIC_RX_BUFFER_NUM=16
CONFIG_ESP_WIFI_DYNAMIC_TX_BUFFER_NUM=16
CONFIG_ESP_WIFI_AMPDU_TX_ENABLED=y
CONFIG_ESP_WIFI_TX_BA_WIN=8
CONFIG_ESP_WIFI_AMPDU_RX_ENABLED=y
CONFIG_ESP_WIFI_RX_BA_WIN=8
CONFIG_ESP_WIFI_RX_IRAM_OPT=y
CONFIG_ESP_WIFI_IRAM_OPT=y
# 9. LWIP config
#----------------
CONFIG_LWIP_TCP_SND_BUF_DEFAULT=11520
CONFIG_LWIP_TCP_WND_DEFAULT=11520
CONFIG_LWIP_TCP_RECVMBOX_SIZE=16
CONFIG_LWIP_UDP_RECVMBOX_SIZE=16
CONFIG_LWIP_TCPIP_RECVMBOX_SIZE=32
CONFIG_LWIP_TCP_SACK_OUT=y
CONFIG_LWIP_TCPIP_CORE_LOCKING=y
CONFIG_LWIP_TCPIP_CORE_LOCKING_INPUT=y
# 10. Optimizations
#-------------------
CONFIG_COMPILER_OPTIMIZATION_SIZE=y
#CONFIG_COMPILER_OPTIMIZATION_PERF=y
# 11. Stats
#-----------
#CONFIG_ESP_HOSTED_FUNCTION_PROFILING=y
CONFIG_ESP_PKT_STATS=y
# 12. Priorities
----------------
CONFIG_IPERF_TRAFFIC_TASK_PRIORITY=18
CONFIG_IPERF_REPORT_TASK_PRIORITY=18
#13. Mem optimizations
#---------------------
CONFIG_FREERTOS_PLACE_FUNCTIONS_INTO_FLASH=y
CONFIG_ESP_DEFAULT_CPU_FREQ_MHZ=120
CONFIG_ESP_DEFAULT_CPU_FREQ_MHZ_120=y
CONFIG_FREERTOS_UNICORE=y
#14. C2 specific opts
#---------------------
CONFIG_ESPTOOLPY_FLASHSIZE_4MB=n
CONFIG_ESPTOOLPY_FLASHSIZE_2MB=y
CONFIG_ESP_DEFAULT_TASK_STACK_SIZE=2048
CONFIG_C2_C5_MODULE_SUB_BOARD=y
#15. For C2 26 MHz XTAL chips only
#---------------------------------
CONFIG_SOC_XTAL_SUPPORT_26M=y
CONFIG_XTAL_FREQ_26=y