fix(13e6): partition + SPI corruption + bootstrap stay-awake

Three problems surfaced during the first 13.3" end-to-end run:

1) LittleFS IntegerDivideByZero on 200 → write /img.bin. Cause: the
   ~3.5 MB SPIFFS in default_16MB.csv can't fit three 960 KB setup
   screens + a 960 KB cached image (~3.84 MB). Switching to a custom
   partitions_13e6.csv with 24 MB LittleFS on the 32 MB flash.

2) Yellow wash across the panel on long SPI bursts. Cause: SPI DMA
   from a PSRAM-backed scratch buffer hits a cache-coherency window —
   the CPU's writes hadn't reached PSRAM yet when DMA read it. Push
   each half in 8 KB chunks through an internal-SRAM (DMA-coherent)
   scratch, and drop the bus clock to 4 MHz to match the 7.3"
   production speed.

3) Bootstrap window (no image yet) was deep-sleeping for 15 s between
   polls — each cycle a ~5 s ROM-boot + Wi-Fi reconnect, so the user
   waited ~20 s × N retries between scanning the setup QR and seeing
   their first photo land. Now normal_operation_impl returns early
   during bootstrap and main.cpp's normal_operation loops with a
   2 s delay, keeping Wi-Fi up. Once the first image arrives, the
   normal scheduled deep sleep takes over.

   Also fixes a related bug Matt called out: a transient TLS hiccup
   during bootstrap was hitting the 5xx fallback path and painting a
   full yellow fill over the green setup QR, leaving the user with
   no claim path. Criterion is now "does /img.bin exist?" (panel has
   something worth showing with a border) rather than "is currentImgId
   set?", so a fresh device with no cached image preserves the setup
   screen through transient network errors.

Diagnostic prints in the panel driver + [op] start/code lines in
normal_operation_impl that proved invaluable during bringup; leaving
them in for now. Tests updated for the new bootstrap semantics
(deep sleep no longer arms on bootstrap-cycle 204/404/5xx); 43/43
native tests pass, 7.3" production build stays byte-identical.

Co-Authored-By: Claude Opus 4.7 (1M context) <noreply@anthropic.com>
This commit is contained in:
2026-05-14 11:50:36 -04:00
parent c75e4c003d
commit 013e49d859
7 changed files with 106 additions and 43 deletions
+26 -17
View File
@@ -107,6 +107,7 @@ inline bool check_reset_button() {
template<typename HTTP>
void normal_operation_impl(const String& mac, HTTP& http, const String& url, Preferences& prefs) {
Serial.println("[op] start GET " + url);
prefs.begin(NVS_NAMESPACE, true);
int32_t currentImgId = prefs.getInt(NVS_KEY_IMG_ID, -1);
bool drawNeeded = prefs.getInt(NVS_KEY_DRAW_NEEDED, 0) != 0;
@@ -162,6 +163,7 @@ void normal_operation_impl(const String& mac, HTTP& http, const String& url, Pre
const char* collectHeaders[] = { "X-Interval-Ms", "X-Image-Id", "X-Image-Sha256", "X-Claimed" };
http.collectHeaders(collectHeaders, 4);
int code = http.GET();
Serial.println("[op] GET code=" + String(code));
// Server confirmed we're claimed → flag clears, regardless of what
// happened to the response body. Without this, every poll forever
@@ -292,27 +294,31 @@ void normal_operation_impl(const String& mac, HTTP& http, const String& url, Pre
// previous cycle.
http.end();
} else {
// Sync failed (5xx, timeout, malformed). Per FR38, the last-good image
// must persist; only the border indicates the error. epd_draw_image_with_border
// falls back to a full fill if the cached file is missing or wrong size,
// so first-boot error still gets a visible signal.
// Sync failed (5xx, timeout, TLS handshake failure → code=-1, etc.).
// Criterion is "does /img.bin exist?", not "is currentImgId >= 0?":
// • file exists → a real photo is on the panel. Draw it with a
// yellow border so the user sees a sync signal without losing it.
// Per FR38, the last-good image must persist.
// • no file → bootstrap window. Panel is showing the setup-claim
// QR which the user still needs to scan. A transient TLS hiccup
// must NOT wipe that to a yellow fill — it would leave the
// recipient with no way to claim the frame until the next 200.
http.end();
displayInitialized = true;
epd_init();
File r = LittleFS.open(IMAGE_PATH, "r");
if (r) {
Serial.println(String("[op] sync fail code=") + String(code) +
" -> drawing image with yellow border");
displayInitialized = true;
epd_init();
epd_draw_image_with_border(r, COLOR_YELLOW, BORDER_THICKNESS_PX);
r.close();
prefs.begin(NVS_NAMESPACE, false);
prefs.putInt(NVS_KEY_ERR_BORDER, 1);
prefs.end();
} else {
Serial.println(String("[op] sync fail code=") + String(code) +
" -> no cached image, falling back to full yellow fill");
epd_fill(COLOR_YELLOW);
" with no cached image; preserving setup screen");
}
prefs.begin(NVS_NAMESPACE, false);
prefs.putInt(NVS_KEY_ERR_BORDER, 1);
prefs.end();
}
// Only power off the display if it was initialized this cycle. Calling
@@ -321,16 +327,19 @@ void normal_operation_impl(const String& mac, HTTP& http, const String& url, Pre
// entire poll interval on every 304 response.
if (displayInitialized) epd_sleep();
// Bootstrap-fast polling: until we've ever displayed an image, ignore
// the schedule and poll every 15 s. Without this, a freshly-claimed
// device whose owner has wakeTimes set to e.g. noon would sit dark for
// up to 24 h before the first photo lands. We re-read img_id from NVS
// because the 200 path persists it AFTER the local var was captured.
// Bootstrap window: the device has never received an image — the user is
// still mid-setup, looking at the green setup QR, waiting for the first
// photo to land. Return WITHOUT arming deep sleep. The caller is expected
// to re-invoke us on a short timer until imgIdAfter goes >= 0, keeping
// WiFi up and the device responsive. The previous "15 s deep-sleep
// between bootstrap polls" wasted ~5 s per cycle on flash boot + WiFi
// reconnect, so end-user wait until first image was ~20 s × N retries.
prefs.begin(NVS_NAMESPACE, true);
int32_t imgIdAfter = prefs.getInt(NVS_KEY_IMG_ID, -1);
prefs.end();
if (imgIdAfter < 0) {
sleepMs = FIRST_IMAGE_POLL_INTERVAL_MS;
Serial.println("[op] bootstrap: no image yet, caller will retry");
return;
}
esp_sleep_enable_timer_wakeup(sleepMs * 1000ULL);