Speed Option 3 builds and harden radio IRQ handling

src/helpers/NRF52Board.cpp

@@ -530,7 +530,9 @@ bool NRF52Board::startOTAUpdate(const char *id, char reply[], bool force_ap) {
     Bluefruit.configPrphBandwidth(BANDWIDTH_MAX);
     Bluefruit.configPrphConn(92, BLE_GAP_EVENT_LENGTH_MIN, 16, 16);
 
-    Bluefruit.begin(1, 0);
+    if (!Bluefruit.begin(1, 0)) {
+      return false;
+    }
     ota_ble_started = true;
 
     // To be consistent OTA DFU should be added first if it exists

src/helpers/radiolib/CustomLLCC68.h

@@ -2,10 +2,12 @@
 
 #include <RadioLib.h>
 
-#define SX126X_IRQ_HEADER_VALID                     0b0000010000  //  4     4     valid LoRa header received
-#define SX126X_IRQ_PREAMBLE_DETECTED           0x04
-
 class CustomLLCC68 : public LLCC68 {
+  uint32_t _preambleMillis = 66;
+  uint32_t _maxPayloadMillis = 3934;
+  uint32_t _activityAt = 0;
+  bool _headerSeen = false;
+
   public:
     CustomLLCC68(Module *mod) : LLCC68(mod) { }
 
@@ -78,10 +80,77 @@ class CustomLLCC68 : public LLCC68 {
     return true;  // success
   }
 
+    int16_t startReceive() override {
+      return LLCC68::startReceive(
+          RADIOLIB_SX126X_RX_TIMEOUT_INF,
+          RADIOLIB_IRQ_RX_DEFAULT_FLAGS | (1UL << RADIOLIB_IRQ_PREAMBLE_DETECTED),
+          RADIOLIB_IRQ_RX_DEFAULT_MASK, 0);
+    }
+
     bool isReceiving() {
-      uint16_t irq = getIrqFlags();
-      bool detected = (irq & SX126X_IRQ_HEADER_VALID) || (irq & SX126X_IRQ_PREAMBLE_DETECTED);
-      return detected;
+      uint32_t irq = getIrqFlags();
+      bool preamble = irq & RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED;
+      bool header = irq & RADIOLIB_SX126X_IRQ_HEADER_VALID;
+      bool headerError = irq & RADIOLIB_SX126X_IRQ_HEADER_ERR;
+      uint32_t now = millis();
+
+      if (headerError) {
+        clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED |
+                      RADIOLIB_SX126X_IRQ_HEADER_VALID |
+                      RADIOLIB_SX126X_IRQ_HEADER_ERR |
+                      RADIOLIB_SX126X_IRQ_SYNC_WORD_VALID);
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
+      if (!header && _headerSeen) {
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
+      if (header) {
+        if (!_headerSeen) {
+          _headerSeen = true;
+          _activityAt = now;
+        }
+        if (now - _activityAt > _maxPayloadMillis) {
+          MESH_DEBUG_PRINTLN("Clearing header IRQ after %ums", _maxPayloadMillis);
+          clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED |
+                        RADIOLIB_SX126X_IRQ_HEADER_VALID |
+                        RADIOLIB_SX126X_IRQ_HEADER_ERR |
+                        RADIOLIB_SX126X_IRQ_SYNC_WORD_VALID);
+          _activityAt = 0;
+          _headerSeen = false;
+          return false;
+        }
+        return true;
+      }
+      if (preamble) {
+        if (_activityAt == 0) {
+          _activityAt = now;
+        }
+        if (now - _activityAt > _preambleMillis) {
+          clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED);
+          _activityAt = 0;
+          MESH_DEBUG_PRINTLN("Clearing preamble IRQ after %ums", _preambleMillis);
+          return false;
+        }
+        return true;
+      }
+
+      _activityAt = 0;
+      _headerSeen = false;
+      return false;
+    }
+
+    void setPreambleMillis(uint32_t preambleMillis) {
+      _preambleMillis = preambleMillis;
+      MESH_DEBUG_PRINTLN("Set _preambleMillis=%u", _preambleMillis);
+    }
+
+    void setMaxPayloadMillis(uint32_t payloadMillis) {
+      _maxPayloadMillis = payloadMillis;
+      MESH_DEBUG_PRINTLN("Set _maxPayloadMillis=%u", _maxPayloadMillis);
     }
 
     bool getRxBoostedGainMode() {
@@ -89,4 +158,4 @@ class CustomLLCC68 : public LLCC68 {
       readRegister(RADIOLIB_SX126X_REG_RX_GAIN, &rxGain, 1);
       return (rxGain == RADIOLIB_SX126X_RX_GAIN_BOOSTED);
     }
-};
+};

src/helpers/radiolib/CustomLLCC68Wrapper.h

@@ -10,11 +10,17 @@ public:
 
 protected:
   bool applyParams(float freq, float bw, uint8_t sf, uint8_t cr) override {
-    return ((CustomLLCC68 *)_radio)->setFrequency(freq) == RADIOLIB_ERR_NONE
+    bool success = ((CustomLLCC68 *)_radio)->setFrequency(freq) == RADIOLIB_ERR_NONE
         && ((CustomLLCC68 *)_radio)->setSpreadingFactor(sf) == RADIOLIB_ERR_NONE
         && ((CustomLLCC68 *)_radio)->setBandwidth(bw) == RADIOLIB_ERR_NONE
         && ((CustomLLCC68 *)_radio)->setCodingRate(cr) == RADIOLIB_ERR_NONE
         && updatePreamble(sf);
+    if (!success) return false;
+
+    PacketMillis pm = calcMaxPacketMillis(sf, bw, cr, preambleLengthForSF(sf));
+    ((CustomLLCC68 *)_radio)->setPreambleMillis(pm.preambleMillis);
+    ((CustomLLCC68 *)_radio)->setMaxPayloadMillis(pm.payloadMillis);
+    return true;
   }
 
 public:

src/helpers/radiolib/CustomLR1110.h

@@ -74,6 +74,15 @@ class CustomLR1110 : public LR1110 {
 
     bool getRxBoostedGainMode() const { return _rx_boosted; }
 
+    int16_t startReceive() override {
+      // Make preamble detection visible to CAD while retaining RadioLib's
+      // normal RX-complete and error events.
+      return LR1110::startReceive(
+          RADIOLIB_LR11X0_IRQ_PREAMBLE_DETECTED,
+          RADIOLIB_IRQ_RX_DEFAULT_FLAGS | (1UL << RADIOLIB_IRQ_PREAMBLE_DETECTED),
+          RADIOLIB_IRQ_RX_DEFAULT_MASK, 0);
+    }
+
     // BUSY high means the chip is asleep (RX duty-cycle sleep window) or mid
     // command; any SPI access would stall until the chip's next listen window.
     bool isChipBusy() {
@@ -95,6 +104,12 @@ class CustomLR1110 : public LR1110 {
         _headerSeen = false;
         return false;
       }
+      if (!header && _headerSeen) {
+        // Another path consumed the header IRQ; reset only our local timer.
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
       if (header) {
         if (!_headerSeen) { _headerSeen = true; _activityAt = now; };
         if (now - _activityAt > _maxPayloadMillis) {

src/helpers/radiolib/CustomSX1262.h

@@ -140,6 +140,15 @@ class CustomSX1262 : public SX1262 {
       return RADIOLIB_ERR_NONE;
     }
 
+    int16_t startReceive() override {
+      // Make preamble detection visible to CAD while retaining RadioLib's
+      // normal RX-complete and error events.
+      return SX1262::startReceive(
+          RADIOLIB_SX126X_RX_TIMEOUT_INF,
+          RADIOLIB_IRQ_RX_DEFAULT_FLAGS | (1UL << RADIOLIB_IRQ_PREAMBLE_DETECTED),
+          RADIOLIB_IRQ_RX_DEFAULT_MASK, 0);
+    }
+
     bool isReceiving() {
       if (isChipBusy()) return false;   // asleep, cannot be mid-receive
 
@@ -154,6 +163,12 @@ class CustomSX1262 : public SX1262 {
         _headerSeen = false;
         return false;
       }
+      if (!header && _headerSeen) {
+        // Another path consumed the header IRQ; reset only our local timer.
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
       if (header) {
         if (!_headerSeen) { _headerSeen = true; _activityAt = now; };
         if (now - _activityAt > _maxPayloadMillis) {

src/helpers/radiolib/CustomSX1268.h

@@ -2,10 +2,12 @@
 
 #include <RadioLib.h>
 
-#define SX126X_IRQ_HEADER_VALID                0b0000010000  //  4     4     valid LoRa header received
-#define SX126X_IRQ_PREAMBLE_DETECTED           0x04
-
 class CustomSX1268 : public SX1268 {
+  uint32_t _preambleMillis = 66;
+  uint32_t _maxPayloadMillis = 3934;
+  uint32_t _activityAt = 0;
+  bool _headerSeen = false;
+
   public:
     CustomSX1268(Module *mod) : SX1268(mod) { }
 
@@ -78,10 +80,77 @@ class CustomSX1268 : public SX1268 {
       return true;  // success
     }
 
+    int16_t startReceive() override {
+      return SX1268::startReceive(
+          RADIOLIB_SX126X_RX_TIMEOUT_INF,
+          RADIOLIB_IRQ_RX_DEFAULT_FLAGS | (1UL << RADIOLIB_IRQ_PREAMBLE_DETECTED),
+          RADIOLIB_IRQ_RX_DEFAULT_MASK, 0);
+    }
+
     bool isReceiving() {
-      uint16_t irq = getIrqFlags();
-      bool detected = (irq & SX126X_IRQ_HEADER_VALID) || (irq & SX126X_IRQ_PREAMBLE_DETECTED);
-      return detected;
+      uint32_t irq = getIrqFlags();
+      bool preamble = irq & RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED;
+      bool header = irq & RADIOLIB_SX126X_IRQ_HEADER_VALID;
+      bool headerError = irq & RADIOLIB_SX126X_IRQ_HEADER_ERR;
+      uint32_t now = millis();
+
+      if (headerError) {
+        clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED |
+                      RADIOLIB_SX126X_IRQ_HEADER_VALID |
+                      RADIOLIB_SX126X_IRQ_HEADER_ERR |
+                      RADIOLIB_SX126X_IRQ_SYNC_WORD_VALID);
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
+      if (!header && _headerSeen) {
+        _activityAt = 0;
+        _headerSeen = false;
+        return false;
+      }
+      if (header) {
+        if (!_headerSeen) {
+          _headerSeen = true;
+          _activityAt = now;
+        }
+        if (now - _activityAt > _maxPayloadMillis) {
+          MESH_DEBUG_PRINTLN("Clearing header IRQ after %ums", _maxPayloadMillis);
+          clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED |
+                        RADIOLIB_SX126X_IRQ_HEADER_VALID |
+                        RADIOLIB_SX126X_IRQ_HEADER_ERR |
+                        RADIOLIB_SX126X_IRQ_SYNC_WORD_VALID);
+          _activityAt = 0;
+          _headerSeen = false;
+          return false;
+        }
+        return true;
+      }
+      if (preamble) {
+        if (_activityAt == 0) {
+          _activityAt = now;
+        }
+        if (now - _activityAt > _preambleMillis) {
+          clearIrqFlags(RADIOLIB_SX126X_IRQ_PREAMBLE_DETECTED);
+          _activityAt = 0;
+          MESH_DEBUG_PRINTLN("Clearing preamble IRQ after %ums", _preambleMillis);
+          return false;
+        }
+        return true;
+      }
+
+      _activityAt = 0;
+      _headerSeen = false;
+      return false;
+    }
+
+    void setPreambleMillis(uint32_t preambleMillis) {
+      _preambleMillis = preambleMillis;
+      MESH_DEBUG_PRINTLN("Set _preambleMillis=%u", _preambleMillis);
+    }
+
+    void setMaxPayloadMillis(uint32_t payloadMillis) {
+      _maxPayloadMillis = payloadMillis;
+      MESH_DEBUG_PRINTLN("Set _maxPayloadMillis=%u", _maxPayloadMillis);
     }
 
     bool getRxBoostedGainMode() {
@@ -89,4 +158,4 @@ class CustomSX1268 : public SX1268 {
       readRegister(RADIOLIB_SX126X_REG_RX_GAIN, &rxGain, 1);
       return (rxGain == RADIOLIB_SX126X_RX_GAIN_BOOSTED);
     }
-};
+};

src/helpers/radiolib/CustomSX1268Wrapper.h

@@ -14,11 +14,17 @@ public:
 
 protected:
   bool applyParams(float freq, float bw, uint8_t sf, uint8_t cr) override {
-    return ((CustomSX1268 *)_radio)->setFrequency(freq) == RADIOLIB_ERR_NONE
+    bool success = ((CustomSX1268 *)_radio)->setFrequency(freq) == RADIOLIB_ERR_NONE
         && ((CustomSX1268 *)_radio)->setSpreadingFactor(sf) == RADIOLIB_ERR_NONE
         && ((CustomSX1268 *)_radio)->setBandwidth(bw) == RADIOLIB_ERR_NONE
         && ((CustomSX1268 *)_radio)->setCodingRate(cr) == RADIOLIB_ERR_NONE
         && updatePreamble(sf);
+    if (!success) return false;
+
+    PacketMillis pm = calcMaxPacketMillis(sf, bw, cr, preambleLengthForSF(sf));
+    ((CustomSX1268 *)_radio)->setPreambleMillis(pm.preambleMillis);
+    ((CustomSX1268 *)_radio)->setMaxPayloadMillis(pm.payloadMillis);
+    return true;
   }
 
 public: