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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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(#3789)
test/hil: replace PCI reset with root-port VBUS cycle for D-state recovery
pci-reset was documented as an FLR, but no controller on either rig has FLR, so
it issued a PCIe secondary bus reset on a live, driver-bound xHCI -- halting the
card until the PVE host was power-cycled, and returning success so the caller
could not tell. It destroyed the ci controller twice.
Replace it with root-cycle, which cuts VBUS at the xHCI root port and touches
only the root hub, so it never takes the per-device lock the wedged ioctl holds.
uhubctl needs -S, or its sysfs backend disconnects the child before cutting
power and blocks on that same lock. Success is proven by the device's sysfs
directory inode changing: node existence proves nothing, and devnum is reused
once the per-bus map wraps.
usbtest.py's hang path invokes it, then confirms via /proc that nothing still
holds the device node. Skill scripts now run from the repo; the drifted
/usr/local/sbin copies are deleted.
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Rename usb-target-debug -> target-debug, usb-debug -> usb-kernel-debug,
usb-recover -> usb-kernel-recover (script filenames unchanged), and make all
debug skills/agents decide tool applicability by which end of the link runs
Linux: TinyUSB may run the device or host stack, and its peer may be a Linux
PC, another TinyUSB board, or a Linux gadget (e.g. Raspberry Pi UDC).
- usbmon: exists only when a Linux PC is the link's host
- usb-kernel-debug: either Linux end; allowlist gains dwc3/libcomposite/udc_core
for the gadget side of a Linux peer
- usb-sniffer: the only full-visibility capture when TinyUSB is the host
- target-debug: covers dcd_* and hcd_*/tuh_ debugging; channel choice by topology
- update target-debugger/hil-operator agents, pre-pr, hil-validate.js, and the
USB_RECOVER path constant in test/hil/usbtest.py
- CLAUDE.md: fold the dcd/hcd datasheet cross-check rule into the read-doc line
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incompatible
The MosChip MCS9990 card is physically removed from the rig: delete its
cases-11/25 SKIP workaround (and the now-orphaned SKIP accounting) from
usbtest.py and refuse to run outright if a DUT ever sits behind one again.
usb_recover.sh gains `hub-cycle <busport>`: uhubctl VBUS cycle of the port
feeding the device, walking upstream (parent hub -> root port) until it
re-enumerates. Verified on the rig: leaf-level recovery (13-4.4 usbtest
device) and full walk to the root port on a dead branch. SKILL.md updated
for the action and the two-Renesas topology (root-port ppps is real; leaf
1a40:0201 hubs fake their "ganged" switching).
Co-Authored-By: Claude Fable 5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01WxUeX4Yn26KibfjvDg2pN9
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Pool/config:
- record real uids (ra8m1_ek), enable usbtest for espressif s3/p4, then
park ra6m5_ek and ra8m1_ek in boards-skip (ra6m5's usbtest/MSC traffic
can kill the uPD720201 host on its ROM firmware; ra8m1 USBHS bring-up
pending); max32666/nrf54lm20 stay enabled - their MosChip flakiness
never wedges
- re-enable device/usbtest on HS boards (mimxrt1064, ch32v307) now that
uPD720201 firmware 2.0.2.6 fixes the command-ring death; mimxrt1015
stays skipped - its HS battery killed the controller on both ROM and
2.0.2.6 firmware (board-specific); match the moved host-test bundles
(f723 <-> rt1064); skip never-passing tests on the new
nrf5340dk/nrf54lm20dk boards and the detached pico host bundle, each
documented with a comment
Host-controller quirk gating in usbtest.py (auto-skip, self-heals on a
healthy xHCI):
- MosChip MCS9990 EHCI: case 25 (int-OUT never scheduled, FRINDEX bug)
and case 11 (unlinked reads complete short/EREMOTEIO)
- Renesas uPD720201 xHCI: firmware-gated. The card must run firmware
>= 2.0.2.6 (RAM-uploaded - it reverts to ROM on every power cycle):
on older firmware the command ring dies under unlink stress (a
Configure Endpoint command stops completing; the hub worker deadlocks
holding the device lock; only a host power cycle recovers; three
boards reproduced it). usbtest.py reads the FW version register (PCI
config 0x6c) and refuses to run at all on older firmware - hil_test
surfaces that as a failed test with the reason. On current firmware
the full 30-case battery runs (validated FS+HS: metro_m4, f723,
f723-DMA all 30/30).
Scheduling (hil_test.py):
- Shuffle each (board, variant)'s test order with a seeded RNG
(HIL_SHUFFLE_SEED to replay) so usbtest batteries and flash churn spread
across the timeline instead of convoying on one controller.
- Per-controller usbtest + flash semaphores: HIL_USBTEST_PARALLEL
(default 4) concurrent usbtest batteries and HIL_FLASH_PARALLEL
(default 8) concurrent flashes per host controller. Profiled on
uPD720201 firmware 2.0.2.6 across 8/1..12/8: wall time falls
22.2/14.3/12.5/10.8 min at usbtest width 1/2/3/4 and plateaus there;
zero controller errors everywhere; first battery case failures
(leaf-hub bandwidth stretch) appear at 12/8, and flash width 12 only
amplifies flasher-hub contention flakes - so 8/4 is the optimum. A
separate battery-window flash throttle was profiled and dropped.
- Give every example a unique hardcoded USB PID (0x4001-0x4022, usbtest
keeps 0x4010) instead of the PID_MAP interface bitmap: different
examples now always re-enumerate back-to-back, even on boards whose
CPU reset does not drop D+ (WCH CH58x), so the EXAMPLE_PID table and
same-PID adjacency reordering in hil_test.py are gone; only the
variant-boundary same-example repeat needs a swap.
- Report matrix: stable columns with the metric-bearing tests pinned
first (usbtest, cdc_msc_throughput, msc_file_explorer[_freertos]),
the rest alphabetical.
Fail fast:
- enum wait budget 8 s on the first attempt, 4 s on retries; dfu waits
are deadline-based so dfu-util's own runtime counts against the
budget.
A device-absent failure now costs ~3-5x a passing test (20-30 s)
instead of 10-30x (47-150 s).
- CI runs hil_test with --retry 1 and no in-run second pass: a broken
fixture fails the job fast instead of holding the self-hosted runner
for hours and blocking other PRs' HIL jobs. hil_test still writes the
.skip sidecar, so a manual re-run attempt only retests what failed.
Review fixes (multi-agent adversarial review of this commit):
- tinyusb_win_usbser.inf: the PID rework moved five CDC examples onto
even PIDs the INF's odd-only DeviceList never matched (legacy-Windows
usbser binding) - appended 0x4006/4008/400a/4020/4022 to both lists.
- usbtest example: USBTEST_TIER is now overridable and the descriptors
and pumps are tier-conditional, so a board whose DCD cannot serve a
tier lowers it instead of skipping the whole example - RA2A1 (RUSB2
with no isochronous pipe) builds at tier 3 via its BOARD_ define; the
host battery follows the tier advertised in bcdDevice. Tier-4 output
verified byte-identical after the refactor.
- dynamic_configuration's second config derived USB_PID + 11 = 0x4018,
colliding with net_lwip_webserver - now USB_PID + 0x0100, outside the
per-example space. tools/check_example_pids.py (pre-commit hook)
enforces PID uniqueness incl. derived and literal idProduct values.
- usbtest.py firmware gate: matched by device ID (uPD720201/720202,
both use the 0x6c FW register), and an unreadable version (setpci
missing/denied) now refuses with its own message instead of
masquerading as "firmware 0x00000000"; noted the gate is necessary
but not sufficient (board-specific kills stay per-board skips).
- hil_test: deadline waits use time.monotonic(); multiprocessing
context pinned to fork (raw semaphores in Pool initargs); flash and
usbtest permits unified into one fail-closed, exception-safe
ctrl_permit (unknown controller takes every slot and logs a warning
instead of silently borrowing slot 0); an all-skipped battery
reports as skip, not "0/0" failure; slow-body polls (mtp, printer,
disk read) go through a shared deadline-based wait_until so their
bodies count against the enum budget; throughput's FS detection
compares serials case-insensitively like every other walk; a missing
MSC read-speed line now fails the host msc_file_explorer test
instead of passing with an empty metric.
Hardening:
- fail fast (15 s) when a driver-registry sysfs write blocks: a wedged
device otherwise turns every subsequent battery into an unkillable
D-state writer and silently hangs the whole run
- usb-recover skill: a VM reboot is not a reliable cure (MosChip hubs
latch up across the PCIe reset); full host power cycle is
Co-Authored-By: Claude Fable 5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01HeF2gZ1M7GWkz6Av4BpKPg
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Binds the kernel usbtest driver (gadget-zero profile), runs the tier-based
battery, auto-recovers kernel-side hangs, and skips cases the host
controller cannot run (MosChip MCS9990 EHCI int-OUT).
Co-Authored-By: Claude Fable 5 <[email protected]>
Claude-Session: https://claude.ai/code/session_01HeF2gZ1M7GWkz6Av4BpKPg
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