Files
RuView/firmware/esp32-csi-node/main/stream_sender.c
Joe 944b7bea77 fix(firmware): retry WiFi forever; add an uplink watchdog
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)
2026-09-04 11:31:58 -04:00

176 lines
6.3 KiB
C

/**
* @file stream_sender.c
* @brief UDP stream sender for CSI frames.
*
* Opens a UDP socket and sends serialized ADR-018 frames to the aggregator.
*/
#include "stream_sender.h"
#include <string.h>
#include "esp_log.h"
#include "esp_timer.h"
#include "lwip/sockets.h"
#include "lwip/netdb.h"
#include "sdkconfig.h"
static const char *TAG = "stream_sender";
static int s_sock = -1;
static struct sockaddr_in s_dest_addr;
/**
* ENOMEM backoff state.
* When sendto fails with ENOMEM (errno 12), we suppress further sends for
* a cooldown period to let lwIP reclaim packet buffers. Without this,
* rapid-fire CSI callbacks can exhaust the pbuf pool and crash the device.
*/
static int64_t s_backoff_until_us = 0; /* esp_timer timestamp to resume */
#define ENOMEM_COOLDOWN_MS 100 /* base backoff; doubles per streak */
#define ENOMEM_COOLDOWN_MAX_MS 2000 /* cap on the exponential backoff */
#define ENOMEM_LOG_INTERVAL 50 /* log every Nth suppressed send */
static uint32_t s_enomem_suppressed = 0;
/* Consecutive ENOMEM episodes without an intervening successful send. A fixed
* 100 ms backoff is too short to drain sustained lwIP/WiFi buffer pressure
* (#1135 bug #1: tier-2 + concurrent TX keeps the node stuck), so the backoff
* grows 100→200→400→…→2000 ms per streak and resets on the first send that
* succeeds. */
static uint32_t s_enomem_streak = 0;
/* Timestamp of the last sendto() the stack accepted, on either path; 0 until
* the node has ever delivered anything. Read by the uplink watchdog in main.c
* -- see the rationale there for why "accepted by the stack" is deliberately
* not "received by the server". */
static int64_t s_last_success_us = 0;
static int sender_init_internal(const char *ip, uint16_t port)
{
s_sock = socket(AF_INET, SOCK_DGRAM, IPPROTO_UDP);
if (s_sock < 0) {
ESP_LOGE(TAG, "Failed to create socket: errno %d", errno);
return -1;
}
memset(&s_dest_addr, 0, sizeof(s_dest_addr));
s_dest_addr.sin_family = AF_INET;
s_dest_addr.sin_port = htons(port);
if (inet_pton(AF_INET, ip, &s_dest_addr.sin_addr) <= 0) {
ESP_LOGE(TAG, "Invalid target IP: %s", ip);
close(s_sock);
s_sock = -1;
return -1;
}
ESP_LOGI(TAG, "UDP sender initialized: %s:%d", ip, port);
return 0;
}
int stream_sender_init(void)
{
return sender_init_internal(CONFIG_CSI_TARGET_IP, CONFIG_CSI_TARGET_PORT);
}
int stream_sender_init_with(const char *ip, uint16_t port)
{
return sender_init_internal(ip, port);
}
int stream_sender_send(const uint8_t *data, size_t len)
{
if (s_sock < 0) {
return -1;
}
/* ENOMEM backoff: if we recently exhausted lwIP buffers, skip sends
* until the cooldown expires. This prevents the cascade of failed
* sendto calls that leads to a guru meditation crash. */
if (s_backoff_until_us > 0) {
int64_t now = esp_timer_get_time();
if (now < s_backoff_until_us) {
s_enomem_suppressed++;
if ((s_enomem_suppressed % ENOMEM_LOG_INTERVAL) == 1) {
ESP_LOGW(TAG, "sendto suppressed (ENOMEM backoff, %lu dropped)",
(unsigned long)s_enomem_suppressed);
}
return -1;
}
/* Cooldown expired — resume sending */
ESP_LOGI(TAG, "ENOMEM backoff expired, resuming sends (%lu were suppressed)",
(unsigned long)s_enomem_suppressed);
s_backoff_until_us = 0;
s_enomem_suppressed = 0;
}
int sent = sendto(s_sock, data, len, 0,
(struct sockaddr *)&s_dest_addr, sizeof(s_dest_addr));
if (sent < 0) {
if (errno == ENOMEM) {
/* Exponential backoff: double the cooldown each consecutive ENOMEM
* (capped) so sustained buffer pressure actually drains instead of
* the node re-failing every 100 ms forever (#1135 bug #1). */
uint32_t shift = s_enomem_streak < 5 ? s_enomem_streak : 5;
uint32_t cooldown = ENOMEM_COOLDOWN_MS << shift;
if (cooldown > ENOMEM_COOLDOWN_MAX_MS) cooldown = ENOMEM_COOLDOWN_MAX_MS;
s_enomem_streak++;
s_backoff_until_us = esp_timer_get_time() + (int64_t)cooldown * 1000;
ESP_LOGW(TAG, "sendto ENOMEM — backing off for %lu ms (streak %lu)",
(unsigned long)cooldown, (unsigned long)s_enomem_streak);
} else {
ESP_LOGW(TAG, "sendto failed: errno %d", errno);
}
return -1;
}
/* A send got through — buffer pressure cleared; reset the backoff streak. */
s_enomem_streak = 0;
s_last_success_us = esp_timer_get_time();
return sent;
}
int stream_sender_send_priority(const uint8_t *data, size_t len)
{
if (s_sock < 0) {
return -1;
}
/* Priority path (#1183): low-rate control packets (feature_state, HEALTH,
* mesh sync) bypass the global ENOMEM backoff gate so the high-rate CSI
* stream cannot starve them. These are ≤48 B at ≤1 Hz — negligible pbuf
* pressure, so they won't re-trigger the crash cascade that the backoff
* (driven by the 50 Hz CSI flood) exists to prevent.
*
* Crucially, an ENOMEM here is reported quietly and does NOT extend the
* global streak/backoff: a tiny control packet failing is a symptom of
* the bulk-stream pressure, not a cause, so it must not feed the cooldown
* that suppresses the next CSI frame. Likewise a success does not reset
* the streak — the bulk path owns that signal. */
int sent = sendto(s_sock, data, len, 0,
(struct sockaddr *)&s_dest_addr, sizeof(s_dest_addr));
if (sent < 0) {
if (errno != ENOMEM) {
ESP_LOGW(TAG, "priority sendto failed: errno %d", errno);
}
return -1;
}
/* Counts for the watchdog: the mesh sync packet rides this path at ~1 Hz,
* and its getting through proves the node's network path is intact even
* when the bulk CSI stream is being suppressed by the ENOMEM backoff. */
s_last_success_us = esp_timer_get_time();
return sent;
}
int64_t stream_sender_last_success_us(void)
{
return s_last_success_us;
}
void stream_sender_deinit(void)
{
if (s_sock >= 0) {
close(s_sock);
s_sock = -1;
ESP_LOGI(TAG, "UDP sender closed");
}
}