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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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