Firmware review pass: BT1035 boot retry, BluetoothJson tests, doc catch-up

BT1035Driver::boot() had zero retry on the reset+AT-init sequence — a
single hardware RESET# pulse followed immediately by AT commands,
with no second attempt if the module didn't come up in time. This is
the most plausible explanation for the intermittent "no spontaneous
UART bytes after hardware reset" / "AT init failed" boot failures
logged in docs/si4684-rf-investigation-report.md and observed again
live this morning on otherwise-identical hardware/wiring — classic
power-up timing jitter, not a permanent fault. Extracted the reset+
init sequence into resetAndInitOnce() and wrapped it in a 3-attempt
retry loop with a short delay between attempts; the one-time GPIO
config and UART driver install stay outside the loop since they don't
need repeating. Root cause of the underlying jitter is still open.

BluetoothJson.hpp was the only *Json.hpp module in the core with zero
host test coverage (status/scan/paired serialisation, auto-reconnect/
connect/speaker parsing) — every sibling module already has one.
Added bluetooth_json_test.cpp following the existing tuner_json_test
pattern; ctest now covers 20 suites instead of 19.

Documentation catch-up, found doing a full firmware re-review at the
user's request:
- POST /api/tuner/calibrate-antenna and the antcap field on
  POST /api/tuner/tune (added in a previous commit, never documented)
  are now in ch-api.tex.
- kFirmwareVersion was still hardcoded "0.8.5" despite the RF fixes,
  BLE provisioning, phone streaming, antenna calibration, and generic
  DSP param API landed since that version's actual release commit
  (0a1188a). Bumped to 0.9.0 everywhere it's mentioned (health JSON,
  the manual's title page, intro, classes, and API chapters).
- instructions.md and docs/TODO.md still described the firmware as
  frozen at 0.8.5 awaiting hardware-in-the-loop testing that has since
  happened extensively; docs/TODO.md's H5 verdict specifically still
  said "suspect U6 RF ground (re-open PCBWay)" for a bug that turned
  out to be firmware, not hardware — actively misleading, corrected.
  Both files now summarise the post-0.8.5 HIL findings and current
  open items (BT1035 root cause, intermittent HTTP unresponsiveness
  under load, antenna-limited signal quality, possibly-undersized 24 KB
  nvs partition).

Verified: idf.py build, doxygen (0 warnings), check-manual-sync,
check_si4684_blobs, ctest (20/20), two-pass xelatex manual build all
green. Flashed and confirmed live: fw reports 0.9.0, BT1035 booted on
the first attempt post-flash.

Co-Authored-By: Claude Sonnet 5 <noreply@anthropic.com>
Claude-Session: https://claude.ai/code/session_0178rASQ6ZETPMUamvpoR2KR
This commit is contained in:
2026-08-19 09:23:36 +02:00
co-authored by Claude Sonnet 5
parent f612335632
commit c0eee4a4ad
11 changed files with 393 additions and 30 deletions
+43 -7
View File
@@ -3,9 +3,13 @@
Agent task list and hardware-in-the-loop backlog. Working directory for all
commands is `Software/`.
**Current firmware:** `0.8.5`BT1035 I2S slave boot init, dual OTA + DSP blob updates, EEPROM identity,
NVS + flash encryption (dev mode), tabbed Web UI with System uploads, CI gate
(4 jobs).
**Current firmware:** `0.9.0`everything in 0.8.5, plus: Si4684 RF
blackout root-caused and fixed (real FM/DAB lock and audio on real
hardware), DAB service list fixed (two rounds), FM ANTCAP antenna
calibration persisted to EEPROM, generic ADAU1701 parameter API, phone PCM
streaming, BLE Wi-Fi provisioning, full FM band scan, BT1035 boot retry.
See "Post-0.8.5 hardware-in-the-loop findings" below and
`docs/si4684-rf-investigation-report.md` for the full story.
**Before writing code, read `AGENTS.md`, `.cursor/rules/`, and
`instructions.md`.** Definition of Done: Apache header, doc blocks,
@@ -62,10 +66,42 @@ verify ADAU replay after reboot.
After H1 passes, trial build with `sdkconfig.defaults.production` overlay on
a sacrificial unit; confirm RELEASE mode policy before shipping.
### H5. Si4684 FM/DAB no-lock — blob integrity checked, verdict: hardware
**Verdict (2026-08-13): blob OK → suspect U6 RF ground (re-open PCBWay)**, not
a firmware/blob defect. Full investigation, evidence, and the two byte-offset
bugs found/fixed while verifying this: [`docs/si4684-rf-investigation-report.md`](si4684-rf-investigation-report.md).
### H5. Si4684 FM/DAB no-lock — RESOLVED, was firmware after all
**Superseded verdict (2026-08-13): blob OK → suspected U6 RF ground, PCBWay
dispute opened.** That verdict was wrong. The actual cause was
`writeCommand()`'s ARG1 byte being mis-offset across FM/DAB tune, seek, and
several status/ack commands — the chip always answered correctly, so every
signal pointed at hardware, but it never actually tuned. Fixed; real FM
lock, real DAB ensemble lock, real audio confirmed live on the same board.
No PCB rework was needed. Full investigation, the wrong initial verdict,
and the eventual root cause: [`docs/si4684-rf-investigation-report.md`](si4684-rf-investigation-report.md).
---
## Post-0.8.5 hardware-in-the-loop findings
The board arrived and testing against it (not just host tests) found real
bugs the host-testable core couldn't catch, since they live in
ESP-IDF-only drivers. Full detail and evidence in
[`docs/si4684-rf-investigation-report.md`](si4684-rf-investigation-report.md).
Short version:
- Si4684 total RF blackout (H5 above) — firmware bug, fixed.
- Si4684→ADAU1701 digital audio silence — `PIN_CONFIG_ENABLE` mutual
exclusion + `SerialInputRegister` polarity, fixed.
- DAB service list empty/garbled — response-parsing offset bugs (two
rounds) plus `DAB_EVENT_INTERRUPT_SOURCE` (0xB300) never configured,
fixed.
- FM front-end auto-tune measurably suboptimal on this board's actual
matching network — ANTCAP calibration swept and persisted to EEPROM,
`POST /api/tuner/calibrate-antenna`.
- BT1035 intermittent boot failure — root cause still unknown, but a
reset+init retry loop (up to 3 attempts) was added since the failure
looked like power-up timing jitter, not a permanent fault.
- **Still open**: BT1035 root cause; intermittent multi-second HTTP
unresponsiveness under load; DAB signal quality still antenna-limited;
24 KB `nvs` partition may be undersized (`saveProfile()` `store_failed`
seen intermittently, error code never captured).
---