test: verify inherited nRF52 optimizer before firmware suites

.github/workflows/run-unit-tests.yml

@@ -98,6 +98,12 @@ jobs:
           python3 -B scripts/check_arduinojson_pin.py --self-test
           python3 -B scripts/check_arduinojson_pin.py
 
+      - name: Verify build-size diagnostics and nRF52 optimizer recipes
+        run: |
+          bash test/test_build_size_detection.sh
+          python3 -B test/test_nrf52_size_profile.py -v
+          python3 -B test/test_rak_combined_build_config.py -v
+
       - name: Run Unit Tests
         run: pio test -e native -e native_kiss_modem -e native_ota_channel -vv
 
@@ -455,7 +461,6 @@ jobs:
         env:
           MESHCORE_REQUIRE_ARM_COMPILER: '1'
         run: |
-          bash test/test_build_size_detection.sh
           python3 -B test/test_firmware_ram.py
           python3 -B test/test_recent_repeater_storage.py -v
           python3 -B test/test_ota_cold_buffers.py -v
@@ -474,7 +479,6 @@ jobs:
 
       - name: Verify opt-in RAK4631 combined Ethernet and OTA modes
         run: |
-          python3 -B test/test_rak_combined_build_config.py -v
           python3 -B test/test_rak_combined_ota.py -v
           python3 -B test/test_rak_ethernet_transmit.py -v
           python3 -B test/test_rak4631_ethernet_runtime.py -v
@@ -482,7 +486,6 @@ jobs:
       - name: Verify nRF52 infrastructure trims and unchanged Companion scope
         run: |
           python3 -B test/test_nrf52_flash_trim.py -v
-          python3 -B test/test_nrf52_size_profile.py -v
           python3 -B test/test_nrf52_tft_font_trim.py -v
           python3 -B test/test_ota_target_names.py -v
           python3 -B test/test_ota_cli_listing.py -v

test/test_build_size_detection.sh

@@ -62,16 +62,16 @@ if run_pio_with_size_detection run -e test > /dev/null 2>&1; then
 fi
 [ ! -e "$test_root/pio-called" ] || fail "PIO ran without diagnostic storage"
 
-# Keep sensors and protocol features while shrinking nRF52 repeater code.
+# Keep sensors and protocol features while inheriting nrf52_base's -Oz.
 PIO_ENV_PLATFORM_BY_NAME[ikoka_nano_nrf_22dbm_repeater]=NRF52_PLATFORM
 PLATFORMIO_BUILD_FLAGS=''
 PLATFORMIO_BUILD_UNFLAGS=''
 apply_nrf52_size_profile ikoka_nano_nrf_22dbm_repeater
-[[ "$PLATFORMIO_BUILD_FLAGS" == *' -Os'* ]] || fail "full-sensor repeater omitted size optimization"
+[ -z "$PLATFORMIO_BUILD_FLAGS" ] || fail "full-sensor repeater added an optimizer override or changed features"
 [[ "$PLATFORMIO_BUILD_UNFLAGS" == *'-Ofast'* ]] || fail "aggressive optimization was not removed"
 [[ "$PLATFORMIO_BUILD_FLAGS" != *'-UENV_INCLUDE_'* ]] || fail "sensor support was reduced"
 
-# The legacy RAK4631 Ethernet image uses the same optimizer without inheriting
+# The legacy RAK4631 Ethernet image inherits the same optimizer without inheriting
 # Full Companion's transport/source-only OTA overlay or reducing its sensors.
 (
   PIO_ENV_PLATFORM_BY_NAME[RAK_4631_companion_radio_ethernet]=NRF52_PLATFORM
@@ -84,8 +84,8 @@ apply_nrf52_size_profile ikoka_nano_nrf_22dbm_repeater
     PLATFORMIO_BOARD_UPLOAD_MAXIMUM_SIZE=712704
     PLATFORMIO_BOARD_BUILD_LDSCRIPT=boards/nrf52840_s140_v6.ld
     apply_nrf52_size_profile RAK_4631_companion_radio_ethernet
-    [ "$PLATFORMIO_BUILD_FLAGS" = "$expected_flags -Os" ] \
-      || fail "Ethernet Companion changed features instead of only optimization ($profile)"
+    [ "$PLATFORMIO_BUILD_FLAGS" = "$expected_flags" ] \
+      || fail "Ethernet Companion added an optimizer override or changed features ($profile)"
     [ "$PLATFORMIO_BUILD_UNFLAGS" = $'-D EXTRAFS=1\n-Ofast' ] \
       || fail "Ethernet Companion removed flags other than aggressive optimization ($profile)"
     [ "$PLATFORMIO_BOARD_UPLOAD_MAXIMUM_SIZE" = 712704 ] \

test/test_rak_combined_build_config.py

@@ -7,6 +7,7 @@ import importlib.util
 import json
 import os
 from pathlib import Path
+import re
 import shlex
 import subprocess
 import tempfile
@@ -30,6 +31,11 @@ class RakCombinedBuildConfigTest(unittest.TestCase):
     def test_matching_profiles_preserve_identity_and_never_run_platformio(self):
         original = (ROOT / "platformio.ini").read_bytes()
         variant = (ROOT / "variants/rak4631/platformio.ini").read_bytes()
+        base_flags = shlex.split(ini(ROOT / "platformio.ini")["nrf52_base"]["build_flags"])
+        base_optimizers = [flag for flag in base_flags
+                           if re.fullmatch(r"-O(?:[0-3sgz]|fast)", flag)]
+        self.assertTrue(base_optimizers)
+        self.assertEqual(base_optimizers[-1], "-Oz")
         with tempfile.TemporaryDirectory(prefix="meshcore-rak-config-") as temp:
             directory = Path(temp)
             marker = directory / "unexpected-platformio"
@@ -58,7 +64,9 @@ class RakCombinedBuildConfigTest(unittest.TestCase):
                 self.assertIn("-D MAX_NEIGHBOURS=50", flags)
                 self.assertNotIn("FLOOD_PACKET_FILTER_SLOTS", flags)
                 self.assertIn("-Ofast", overlay["build_unflags"])
-                self.assertIn("-Os", flags)
+                self.assertEqual([flag for flag in shlex.split(flags)
+                                  if re.fullmatch(r"-O(?:[0-3sgz]|fast)", flag)], [],
+                                 "trial overlays must inherit canonical -Oz without overriding it")
                 self.assertIn("-DLORA_FREQ=910.525", flags)
                 self.assertIn(str(overlay_path), config["platformio"]["extra_configs"])
                 self.assertEqual(hashlib.sha256(config_path.read_bytes()).hexdigest(), item["config_sha256"])