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A node that lost WiFi could give up permanently. The disconnect handler counted retries in s_retry_num, which is only ever cleared on a successful IP_EVENT_STA_GOT_IP, so it accumulated across the node's entire uptime. After ten cumulative disconnects it set WIFI_FAIL_BIT and never called esp_wifi_connect() again. No backoff reset, no periodic retry, no reboot. Only a power cycle cleared it. MEASURED 2026-08-30: the AP serving the fleet took a firmware update and rebooted at ~03:38. All three wall-mounted nodes stopped delivering within three minutes of each other (nodes 0 and 1 at 03:37:03, to the second) and none recovered for 5.5-7.5 hours, until each was physically unplugged. CSI capture ran the whole time -- node 0's sync sequence advanced 16600 -> 46340 at a steady ~30/s while it was invisible to the server -- because capture is driver-level and needs no IP. The boards looked alive on a bench and dead to the aggregator. Retry is now unbounded with 500 ms -> 30 s exponential backoff, scheduled on an esp_timer one-shot so esp_wifi_connect() is never reached through a delay inside the event handler. Two things that were conflated are now separate: WIFI_BOOT_WAIT_ATTEMPTS only releases app_main from its startup wait so the rest of the node can boot; nothing stops the node retrying. The uplink watchdog covers the failures we have not diagnosed: no successful send for CONFIG_UPLINK_WATCHDOG_TIMEOUT_S restarts the node. The signal is a successful sendto(), which on UDP means the stack accepted the datagram, NOT that the server received it -- so stopping the aggregator cannot reboot the fleet. It arms on the first successful send rather than at boot, so a node powered up while the AP is down does not reboot-loop; the unbounded reconnect owns that case. The timeout is 1200 s, sized from a 112-minute soak rather than a guess: 30 observed silences across two nodes, median 225 s, one 510 s outlier that looked like two cycles running together. An earlier 120 s would have rebooted healthy nodes every few minutes, and even 600 s left only 90 s of margin over an event already seen once. Do not lower it below ~900 s while the ~225 s stalls are unexplained; a needless reboot re-runs ESP-NOW leader election and discards mesh time-sync state. Also guards thermal.c's apply_tx_power behind CONFIG_THERMAL_THROTTLE so a monitor-only build (the default, and what is on the wall) stops warning about an unused function. Kconfig gains CSI_GATE_MESH_ALIGNED here alongside the watchdog options; its implementation lands in a later commit and the option is inert until then. Co-Authored-By: claude-flow <ruv@ruv.net> (cherry picked from commit bb6d954de68fd4d542e191fd5e82c753f67a9874)
176 lines
6.3 KiB
C
176 lines
6.3 KiB
C
/**
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* @file stream_sender.c
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* @brief UDP stream sender for CSI frames.
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*
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* Opens a UDP socket and sends serialized ADR-018 frames to the aggregator.
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*/
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#include "stream_sender.h"
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#include <string.h>
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#include "esp_log.h"
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#include "esp_timer.h"
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#include "lwip/sockets.h"
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#include "lwip/netdb.h"
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#include "sdkconfig.h"
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static const char *TAG = "stream_sender";
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static int s_sock = -1;
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static struct sockaddr_in s_dest_addr;
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/**
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* ENOMEM backoff state.
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* When sendto fails with ENOMEM (errno 12), we suppress further sends for
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* a cooldown period to let lwIP reclaim packet buffers. Without this,
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* rapid-fire CSI callbacks can exhaust the pbuf pool and crash the device.
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*/
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static int64_t s_backoff_until_us = 0; /* esp_timer timestamp to resume */
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#define ENOMEM_COOLDOWN_MS 100 /* base backoff; doubles per streak */
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#define ENOMEM_COOLDOWN_MAX_MS 2000 /* cap on the exponential backoff */
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#define ENOMEM_LOG_INTERVAL 50 /* log every Nth suppressed send */
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static uint32_t s_enomem_suppressed = 0;
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/* Consecutive ENOMEM episodes without an intervening successful send. A fixed
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* 100 ms backoff is too short to drain sustained lwIP/WiFi buffer pressure
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* (#1135 bug #1: tier-2 + concurrent TX keeps the node stuck), so the backoff
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* grows 100→200→400→…→2000 ms per streak and resets on the first send that
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* succeeds. */
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static uint32_t s_enomem_streak = 0;
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/* Timestamp of the last sendto() the stack accepted, on either path; 0 until
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* the node has ever delivered anything. Read by the uplink watchdog in main.c
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* -- see the rationale there for why "accepted by the stack" is deliberately
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* not "received by the server". */
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static int64_t s_last_success_us = 0;
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static int sender_init_internal(const char *ip, uint16_t port)
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{
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s_sock = socket(AF_INET, SOCK_DGRAM, IPPROTO_UDP);
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if (s_sock < 0) {
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ESP_LOGE(TAG, "Failed to create socket: errno %d", errno);
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return -1;
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}
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memset(&s_dest_addr, 0, sizeof(s_dest_addr));
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s_dest_addr.sin_family = AF_INET;
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s_dest_addr.sin_port = htons(port);
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if (inet_pton(AF_INET, ip, &s_dest_addr.sin_addr) <= 0) {
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ESP_LOGE(TAG, "Invalid target IP: %s", ip);
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close(s_sock);
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s_sock = -1;
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return -1;
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}
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ESP_LOGI(TAG, "UDP sender initialized: %s:%d", ip, port);
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return 0;
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}
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int stream_sender_init(void)
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{
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return sender_init_internal(CONFIG_CSI_TARGET_IP, CONFIG_CSI_TARGET_PORT);
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}
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int stream_sender_init_with(const char *ip, uint16_t port)
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{
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return sender_init_internal(ip, port);
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}
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int stream_sender_send(const uint8_t *data, size_t len)
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{
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if (s_sock < 0) {
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return -1;
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}
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/* ENOMEM backoff: if we recently exhausted lwIP buffers, skip sends
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* until the cooldown expires. This prevents the cascade of failed
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* sendto calls that leads to a guru meditation crash. */
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if (s_backoff_until_us > 0) {
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int64_t now = esp_timer_get_time();
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if (now < s_backoff_until_us) {
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s_enomem_suppressed++;
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if ((s_enomem_suppressed % ENOMEM_LOG_INTERVAL) == 1) {
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ESP_LOGW(TAG, "sendto suppressed (ENOMEM backoff, %lu dropped)",
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(unsigned long)s_enomem_suppressed);
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}
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return -1;
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}
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/* Cooldown expired — resume sending */
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ESP_LOGI(TAG, "ENOMEM backoff expired, resuming sends (%lu were suppressed)",
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(unsigned long)s_enomem_suppressed);
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s_backoff_until_us = 0;
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s_enomem_suppressed = 0;
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}
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int sent = sendto(s_sock, data, len, 0,
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(struct sockaddr *)&s_dest_addr, sizeof(s_dest_addr));
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if (sent < 0) {
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if (errno == ENOMEM) {
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/* Exponential backoff: double the cooldown each consecutive ENOMEM
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* (capped) so sustained buffer pressure actually drains instead of
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* the node re-failing every 100 ms forever (#1135 bug #1). */
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uint32_t shift = s_enomem_streak < 5 ? s_enomem_streak : 5;
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uint32_t cooldown = ENOMEM_COOLDOWN_MS << shift;
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if (cooldown > ENOMEM_COOLDOWN_MAX_MS) cooldown = ENOMEM_COOLDOWN_MAX_MS;
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s_enomem_streak++;
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s_backoff_until_us = esp_timer_get_time() + (int64_t)cooldown * 1000;
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ESP_LOGW(TAG, "sendto ENOMEM — backing off for %lu ms (streak %lu)",
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(unsigned long)cooldown, (unsigned long)s_enomem_streak);
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} else {
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ESP_LOGW(TAG, "sendto failed: errno %d", errno);
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}
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return -1;
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}
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/* A send got through — buffer pressure cleared; reset the backoff streak. */
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s_enomem_streak = 0;
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s_last_success_us = esp_timer_get_time();
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return sent;
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}
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int stream_sender_send_priority(const uint8_t *data, size_t len)
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{
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if (s_sock < 0) {
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return -1;
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}
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/* Priority path (#1183): low-rate control packets (feature_state, HEALTH,
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* mesh sync) bypass the global ENOMEM backoff gate so the high-rate CSI
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* stream cannot starve them. These are ≤48 B at ≤1 Hz — negligible pbuf
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* pressure, so they won't re-trigger the crash cascade that the backoff
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* (driven by the 50 Hz CSI flood) exists to prevent.
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*
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* Crucially, an ENOMEM here is reported quietly and does NOT extend the
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* global streak/backoff: a tiny control packet failing is a symptom of
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* the bulk-stream pressure, not a cause, so it must not feed the cooldown
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* that suppresses the next CSI frame. Likewise a success does not reset
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* the streak — the bulk path owns that signal. */
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int sent = sendto(s_sock, data, len, 0,
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(struct sockaddr *)&s_dest_addr, sizeof(s_dest_addr));
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if (sent < 0) {
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if (errno != ENOMEM) {
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ESP_LOGW(TAG, "priority sendto failed: errno %d", errno);
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}
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return -1;
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}
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/* Counts for the watchdog: the mesh sync packet rides this path at ~1 Hz,
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* and its getting through proves the node's network path is intact even
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* when the bulk CSI stream is being suppressed by the ENOMEM backoff. */
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s_last_success_us = esp_timer_get_time();
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return sent;
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}
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int64_t stream_sender_last_success_us(void)
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{
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return s_last_success_us;
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}
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void stream_sender_deinit(void)
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{
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if (s_sock >= 0) {
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close(s_sock);
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s_sock = -1;
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ESP_LOGI(TAG, "UDP sender closed");
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}
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}
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