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Two layers whose cost was a contract to reason about rather than an outcome.
SYSFS_UNKNOWN was a three-valued return five files had to keep apart, and
misreading unknown as absence was silent: a healthy board reported as a firmware
regression. What it guarded is real -- `serial` is served by usb_string_attr,
which takes usb_lock_device_interruptible (v6.12.96 sysfs.c:141-143), the same
lock a wedged usbfs ioctl holds -- so the BOUND stays, on every caller by
default. usb_scan reads `serial` on every device matching the VID, and hil_lock's
controller_of does that on essentially every board, so one wedged DUT would
otherwise stall every worker, not one. What goes is the third value.
read_sysfs now returns str or None, and the question the third value existed to
answer is asked directly instead, by two predicates that say which question they
answer: sysfs_stranded() is process-wide and sticky, for hil_pool_check's footer
("could anything here be the tool losing sight of healthy hardware?"), and
path_stranded(path) is per-device, which is what usbtest needs to tell a DUT
whose `serial` is held under device_lock from one that genuinely left the bus --
that difference decides whether it performs driver-registry writes that take the
uninterruptible device_lock.
Gone: _SysfsUnknown, SYSFS_UNKNOWN, sysfs_blind, sysfs_blind_note,
note_sysfs_strand, the cross-process blindness publishing and its report banner,
usb_scan's (list, bool) return, usbtest's inconclusive abort, _blind_note's slot
in the result tuple, and bounded_open, whose last caller went in the previous
commit.
The strand memo is rewritten around the one invariant that makes it safe to
reuse: it is keyed by the path's kernfs inode, captured BEFORE the read. A
busport does not change when a board returns to the same physical port, so a
path-only blacklist outlives the wedge and hil_pool_check's own recovery flow --
reset, reflash, wait_device polling that busport -- would never look at the
board again. A re-enumeration destroys the kernfs node and makes a new one, so a
changed inode is the all-clear. Two ceilings bound different things: per path
(_PATH_STRAND_MAX) for a board that flaps while still wedged, and per process
(_STRAND_MAX) as a backstop against RLIMIT_NOFILE, counted per PATH rather than
per reader because hil_pool_check runs four poll threads over one bus.
A board the pool guard never reached is now reported as run-aborted rather than
pool-timed-out, and outranks a stale board-locked cell for the same reason the
pool-timeout cell does.
Both predicates answer conservatively where they are consulted before something
irreversible. path_stranded() covers the paths read_sysfs answered None for
WITHOUT reading -- past _STRAND_MAX it declines to start another reader, and
vouching for a path nobody looked at hands usbtest's fail-CLOSED guard a
fabricated all-clear, running remove_id/unbind against a wedged device. usbtest's
startup lookup carries the same caveat hil_test's absent arm already did, because
its stderr is relayed verbatim into the report cell.
strand_note() survives the removal for the same reason master had it: every
caller that can say "not found" needs the same sentence, and the one site left to
re-invent it got missed -- a wedged-but-enumerated printer was reported as an
enumeration failure, sending a maintainer after firmware.
The two predicates are not interchangeable, and usbtest needs both. Its per-case
verdict is per-DUT -- a peer that stranded at case 2 must not make our board
report wedged at case 29 -- but the finally block's cleanup is process-wide:
remove_id plus an unbind of EVERY interface under the driver, including that
peer's, each taking the uninterruptible device_lock. So the verdict uses
path_stranded() and the global cleanup stays gated on sysfs_stranded().
USBTEST_RECOVERY_BUDGET was an independent 250s that could not actually contain
the ladder it reserved for, which is why usbtest.py carried a _time_left() gate
re-deciding before every step -- with a bare '- 35' for costs paid downstream
that nobody could re-derive. Between them the two produced a recovery that
skipped its own steps for most real hangs.
The reserve is now derived from the bounds usbtest itself declares, per flasher
and per target: a probe reset, a reflash, and the Rescue-DP POR plus retry a
wedged RP DAP needs, plus the settles and hil_util.REAP_GRACE for each bounded
step. The Rescue-DP legs are openocd-only and gated on the RP target cfg, and
a stub reset is screened out, so the reserve tracks each board's real ladder
instead of one fleet number: 390s for the two RP boards -- whose ladder the old
250 could not contain, which is exactly why the gates skipped their steps --
190s for the other seventeen probe-reset boards, and 150s for esptool and
lm4flash, whose reset is a no-op. Changing a bound in usbtest moves the
reserve with it, and a unit test asserts it covers the ladder.
With the room actually reserved, the child runs the ladder straight through:
recovery_steps, _time_left, the three per-step gates and the parsed-but-unused
--outer-timeout are gone. What stays is what decides outcomes -- the convoy_safe
gate, reset-before-reflash, the no_op screen so a stub that resets nothing is not
claimed, and wedged_pids() as the arbiter, because a clean flash only proves the
probe wrote the MCU.
hil_util.py 616 -> 514 lines.
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Every PR built all 74 legs (2494 example builds on GHA cmake alone) and flashed
all 30 rig boards, whatever it touched. One classifier now walks the PR diff twice
and answers three questions: which families to build, which examples per family,
and which boards run which tests. Fail-open throughout - anything no rule
classifies, any exception, any unusable output falls back to the full matrix, and
a master push always builds everything.
test/hil/helper/hil_select.py moves to tools/ci_select.py: it is no longer HIL-only,
and tools/ is where the build side can import it. test_hil_select.py follows it as
test_ci_select.py.
Rules (docs/superpowers/specs/2026-08-19-ci-build-family-filter-design.md holds the
full table): a port selects the families whose family.cmake references it, and its
role - a dcd change skips host examples and vice versa; a class selects only the
examples whose tusb_config.h enables its CFG_TU[DH]_ macro, following cross-class
includes; an example selects itself; hw/bsp selects its family or board; hw/mcu and
lib select whoever references them. CMake is the reference for all of it - make
follows whatever cmake decides, family.mk is never scanned.
Empty means empty (maintainer ruling): a rule that classifies a path to nothing
selects nothing. Ports no family references, classes no config enables, libs no
example builds and hw/mcu paths that resolve nowhere are all real - nothing
compiles them, so nothing can validate them, and the master-push build is the net.
Structural tests pin each such case with an explicit allowlist, so the day one
stops being empty it fails pre-commit instead of silently narrowing CI.
Per-example builds: build.py grows a repeatable -e, resolved against the targets
CMake actually registered and batched into one `cmake --build --target a b c`.
build_utils mirrors CMake's family_filter (the whole FAMILY_MCUS list, ${...} and
string(TOUPPER ...) resolved) for the cmake side, while the make side keeps
master's algorithm verbatim - the two build systems answer differently and a shared
answer breaks lpc54's make link. hil-build gains this even on a full selection:
1702 example builds become 515.
Transport: the selection travels as a file, never an argv or env var - a mass-sweep
diff selects 261 KB against a 128 KiB exec limit, and E2BIG would fail the step
before its own fallback could run. CircleCI carries the example map inside the
generated config (pipeline parameters cap at 512 chars), swapped into the parameter
defaults by sentinel match, and drops the scoping wholesale if that rewrite fails.
Every PR-derived value written to $GITHUB_ENV/$GITHUB_OUTPUT is character-screened.
Code metrics follow the scoping: metrics.py emits per-example totals, and
metrics_pair_compare compares the (board, example) pairs present on both sides
instead of a scoped run against a full-matrix average.
The selector's own suite gates it in both providers: a selector that exits 0 with
valid-but-wrong JSON is the one failure fail-open cannot catch, so a red suite
means the full matrix.
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A wedged USB device used to take the whole HIL run with it. Every worker that
touched the poisoned node blocked uninterruptibly, the pool could not be joined,
map_async discarded every board's result, and the job ran to the GitHub ceiling
with no report at all -- while the self-hosted runner's single job slot stayed
occupied and every queued job waited behind it.
Bound the calls a worker makes itself. read_sysfs, bounded_open and run_cmd all
answer within a wall clock; read_sysfs distinguishes "absent" from "unknown",
because a blocked read is not evidence of absence, and caps stranded readers at
four (each costs a thread and an fd for the life of the process) after which the
worker declares itself blind. mtype, the gio unmount, the libmtp session and the
arecord/iperf reaps go through those bounds; the MTP session runs in a disposable
subprocess, since libmtp's ctypes calls block unkillably in D state.
Bound the run. A pool guard (HIL_POOL_TIMEOUT, 60 min) fires before any job
ceiling and still writes a report. When the pool will not shut down, the sweep
kills what the workers spawned -- descendants, not just direct children, since
flashers run in their own session -- confirms each kill actually landed, and
exits early so the runner is freed. Whatever survived is named in the report.
Deliberately shallow past that point. We do not re-scan process groups, prove
pid ownership, or escalate through sudo: a root-owned survivor is reported, not
force-killed, because signalling a pid we cannot prove is ours is the worse
failure, and the job ceiling backstops whatever this misses. A D-state holder
was never killable anyway.
Recover instead of reporting a wedge. A HUNG usbtest case reflashes its own DUT
through its roster flasher, but only where the flasher can reach its probe past
a poisoned node -- openocd pinned to a validated vid_pid, or esptool. Where it
cannot, the run says so rather than reserving budget for a path that cannot fire.
Raise the CI ceilings above the pool guard so the guard fires first and still
writes its report, and pin --retry 1 on every HIL leg: the guard is a flat
constant and does not scale with max_retry, so argparse's default of 3 would
triple the serialized usbtest tail against an unchanged guard.
Split the module: execution in hil_test/hil_flash/usbtest, infrastructure in
helper/ (locking, health, selection, shared bounded IO), and the two matrix
generators into .github/scripts/ -- ci_set_matrix.py sat in workflows/, where
GitHub treats every file as a workflow definition. 193 tests cover the bounded
paths, the kill ladder, the guard and the selector against synthetic /proc trees
and PATH-injected fakes; a real wedge cannot be manufactured on demand.
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by flasher extension (#3804)
test/hil: one openocd flasher, per-board verify and firmware extension
The four WCH boards move to `openocd`, leaving one flasher for all.
`verify` is now a per-board opt-out, not dropped fleet-wide: WCH cannot read flash back
over the WCH-Link sdi transport; the other seven openocd boards can, and say so explicitly.
FLASHER_SUFFIX decides each flasher's extension once — find_firmware returns the full path
and the flashers pass it through, so a build with only the wrong artifact is skipped rather
than failed mid-flash. --skip-flash bypasses the filter.
rescue_openocd() power-on-resets a wedged RP2040/RP2350 via its Rescue DP from the flash
retry; the probe has no reset line.
Drops unused openocd_adi, stflash, wlink_rs and uniflash, parks the unstable ra6m5_ek, and
tests that every roster flasher name dispatches.
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probes (#3794)
test/hil: add board-pool health check, split hil_test into focused modules (#3794)
Add test/hil/hil_pool_check.py: per-board rig health scan — probe presence,
light-example flash (dfu_runtime; device_info + serial check for host-only
boards), uid re-enumeration, safe recovery (probe authorized-toggle, board
reset), verified board_test re-park, USB topology report, and a markdown
summary table. Missing firmware is built on the spot (tools/build.py, idf.py
for espressif, one get_deps retry); row statuses: ok, flash-failed, failed,
locked. Board locks are always respected, never bypassed.
Refactor hil_test.py into hil_lock.py (flock protocol, controller permits,
hold/release/status CLI; replaces board_lock.py) and hil_flash.py (flashers,
find_firmware, run_cmd). Update WCH probe uids and the board roster in
tinyusb.json; add the hil-pool-check skill.
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