Repair constrained nRF52 release builds and retain size-failure diagnostics

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

@@ -116,6 +116,7 @@ jobs:
 
       - name: Verify firmware memory budgets and nRF52 Bluetooth startup
         run: |
+          bash test/test_build_size_detection.sh
           python3 -B test/test_firmware_ram.py
           python3 -B test/test_cascade_release_package.py
           python3 -B test/test_t096_full_memory.py

build.sh

@@ -2696,6 +2696,9 @@ requires_dram_limited_neighbors() {
   # 8 KiB static reserve at 254 neighbors. Use their board-declared 50-entry
   # tables when the OTA manager is included.
   case "${1,,}" in
+    heltec_t096_repeater_lora_ota_no_external_sensors|\
+    heltec_t1_repeater_lora_ota_no_external_sensors)
+      return 0 ;;
     generic_e22_sx1262_repeater_lora_ota_no_external_sensors|\
     generic_e22_sx1268_repeater_lora_ota_no_external_sensors|\
     heltec_v2_repeater_lora_ota_no_external_sensors|\
@@ -3266,7 +3269,8 @@ apply_nrf52_size_profile() {
   if [ "${PIO_ENV_PLATFORM_BY_NAME[$env_name]:-}" != "NRF52_PLATFORM" ]; then
     return 0
   fi
-  if ! is_nrf52_companion_radio_full_target "$env_name" \
+  if ! is_repeater_role_target "$env_name" \
+      && ! is_nrf52_companion_radio_full_target "$env_name" \
       && { ! is_lora_ota_build "$env_name" \
            || ! is_lora_ota_only_target "$env_name"; }; then
     return 0
@@ -3276,10 +3280,26 @@ apply_nrf52_size_profile() {
   # runtime software Ed25519 fallback is linked alongside CC310, that setting
   # fully expands repeated Curve25519 arithmetic and wastes tens of kilobytes.
   # Keep hardware crypto, RNG mixing, the software fallback, and board features;
-  # select the size optimizer for both constrained self-updating images and
-  # Full Companion source images, especially their diagnostic profile.
+  # select the size optimizer for repeaters, constrained self-updating images
+  # and Full Companion source images, especially their diagnostic profile.
+  # Full-sensor repeaters also need this after adding the second radio profile;
+  # changing optimization preserves their sensors and protocol features.
   append_platformio_build_unflags "-Ofast"
   export PLATFORMIO_BUILD_FLAGS="${PLATFORMIO_BUILD_FLAGS} -Os"
+
+  # These color-display repeaters reserve a 64 KiB reset-retained OTA arena
+  # plus a 25 KiB framebuffer. Keep their board-declared 50 neighbours and
+  # the complete flood-rule engine with a smaller table so runtime startup
+  # allocations also fit; do not lower the heap qualification requirement.
+  case "${env_name,,}" in
+    heltec_t096_repeater_lora_ota_no_external_sensors|\
+    heltec_t1_repeater_lora_ota_no_external_sensors)
+      append_platformio_build_unflags "-DFLOOD_PACKET_FILTER_SLOTS=63"
+      export PLATFORMIO_BUILD_FLAGS="${PLATFORMIO_BUILD_FLAGS} -DFLOOD_PACKET_FILTER_SLOTS=16"
+      record_build_reduction \
+        "mesh.flood_rules limited to 16 by measured internal RAM; complete rule engine, color display, GPS, and OTA retained"
+      ;;
+  esac
 }
 
 apply_lora_ota_no_external_sensors_profile() {
@@ -4029,6 +4049,29 @@ restore_platformio_build_flags() {
   fi
 }
 
+run_pio_with_size_detection() {
+  local build_output_log
+  local build_status
+  local -a output_statuses
+  # SCons can delete the environment's build directory when flags change.
+  # A tee log inside that directory is then unlinked while still open, hiding
+  # the size error from the measured-size fallback after PlatformIO exits.
+  build_output_log=$(mktemp "${TMPDIR:-/tmp}/meshcore-build-XXXXXX.log") || return 1
+  pio "$@" 2>&1 | tee "$build_output_log"
+  output_statuses=("${PIPESTATUS[@]}")
+  build_status=${output_statuses[0]}
+  if [ "${output_statuses[1]}" -ne 0 ]; then
+    build_status=1
+  elif [ "$build_status" -ne 0 ] \
+      && grep -Eiq \
+        'will not fit in region|region .+ overflowed by|section .+ will not fit|sketch too big|program size is greater than maximum|exceed(s|ing).*(flash|partition|app)' \
+        "$build_output_log"; then
+    build_status=42
+  fi
+  rm -f -- "$build_output_log"
+  return "$build_status"
+}
+
 build_firmware() {
   local env_name=$1
   local pio_env_name
@@ -4271,17 +4314,8 @@ build_firmware() {
     pio_run_args+=(-t mergebin)
   fi
   if [ "$build_status" -eq 0 ]; then
-    local build_output_dir="${PIO_BUILD_DIR_OVERRIDE:-${PLATFORMIO_BUILD_DIR:-.pio/build}}/${pio_env_name}"
-    local build_output_log="${build_output_dir}/.meshcore-build-output.log"
-    mkdir -p -- "$build_output_dir"
-    pio "${pio_run_args[@]}" 2>&1 | tee "$build_output_log"
-    build_status=${PIPESTATUS[0]}
-    if [ "$build_status" -ne 0 ] \
-        && grep -Eiq \
-          'will not fit in region|region .+ overflowed by|section .+ will not fit|sketch too big|program size is greater than maximum|exceed(s|ing).*(flash|partition|app)' \
-          "$build_output_log"; then
-      build_status=42
-    fi
+    run_pio_with_size_detection "${pio_run_args[@]}"
+    build_status=$?
   fi
   if [ "$build_status" -eq 0 ]; then
     collect_build_artifacts "$env_name" "$env_platform" "$pio_env_name" "$firmware_filename"

docs/releases/1.17.1.6.md

@@ -95,6 +95,20 @@ before choosing an update method.
 
 ## Reproduce the release
 
+Follow-up builds repair the constrained profiles without relaxing qualification:
+
+- nRF52 repeaters use `-Os` instead of `-Ofast`, retaining their sensor drivers
+  and protocol features while reducing flash use.
+- T096 and T1 LoRa OTA repeaters retain their board-defined 50 neighbors and
+  use 16 flood-rule slots. The complete rule engine, color display, GPS and OTA
+  remain enabled. The T096's available startup heap rises from 72,492 to 81,468
+  bytes, and the T1's from 72,868 to 81,844 bytes. Required startup allocations
+  fall from 88,410 to 79,010 bytes. These are linked capacity checks, not soak
+  measurements. Full Companion capacities are unchanged.
+- Size-failure detection keeps its temporary output log outside PlatformIO's
+  build tree, so SCons cleanup cannot erase the evidence needed by the measured
+  size fallback. CI exercises cleanup, ordinary compiler failures and log errors.
+
 Use a clean checkout of the release commit and a fresh output directory:
 
 ```bash

test/test_build_size_detection.sh

@@ -0,0 +1,94 @@
+#!/usr/bin/env bash
+set -euo pipefail
+cd "$(dirname "$0")/.."
+source build.sh
+
+fail() { echo "test_build_size_detection: $*" >&2; exit 1; }
+test_root=$(mktemp -d "${TMPDIR:-/tmp}/meshcore-size-tests.XXXXXX")
+test_root=$(realpath "$test_root")
+[[ "$test_root" == /*/meshcore-size-tests.* ]] || fail "unexpected temporary path"
+trap 'rm -rf -- "$test_root"' EXIT
+export TMPDIR=$test_root
+managed_dir=$test_root/build/test
+pio() {
+  # Model the real SCons cleanup that previously unlinked the tee log.
+  [[ "$managed_dir" == "$test_root/"* ]] || return 99
+  rm -rf -- "$managed_dir"
+  touch "$test_root/pio-called"
+  printf '%s\n' "$pio_message"
+  return "$pio_result"
+}
+
+check_status() {
+  local expected=$1 actual=0
+  mkdir -p "$managed_dir"
+  if run_pio_with_size_detection run -e test > "$test_root/output" 2>&1; then
+    actual=0
+  else
+    actual=$?
+  fi
+  [ "$actual" -eq "$expected" ] || fail "expected status $expected, got $actual"
+  [ ! -d "$managed_dir" ] || fail "fake PlatformIO did not clean its build directory"
+  if compgen -G "$test_root/meshcore-build-*.log" > /dev/null; then
+    fail "temporary build-output log was not released"
+  fi
+}
+
+pio_result=1
+for pio_message in \
+  "firmware.elf section .text will not fit in region FLASH" \
+  "region FLASH overflowed by 43080 bytes" \
+  "Error: The program size is greater than maximum allowed"; do
+  check_status 42
+  grep -Fq "$pio_message" "$test_root/output" || fail "compiler output was lost"
+done
+pio_message='error: missing declaration'
+check_status 1
+pio_result=2
+check_status 2
+pio_result=0
+pio_message='compilation succeeded'
+check_status 0
+
+# An output failure must not look like a successful or merely oversized build.
+tee() { cat > /dev/null; return 1; }
+check_status 1
+unset -f tee
+rm -f "$test_root/pio-called"
+TMPDIR=$test_root/missing
+if run_pio_with_size_detection run -e test > /dev/null 2>&1; then
+  fail "missing log directory was accepted"
+fi
+[ ! -e "$test_root/pio-called" ] || fail "PIO ran without diagnostic storage"
+
+# Keep sensors and protocol features while shrinking nRF52 repeater code.
+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
+[[ "$PLATFORMIO_BUILD_FLAGS" == *' -Os'* ]] || fail "full-sensor repeater omitted size optimization"
+[[ "$PLATFORMIO_BUILD_UNFLAGS" == *'-Ofast'* ]] || fail "aggressive optimization was not removed"
+[[ "$PLATFORMIO_BUILD_FLAGS" != *'-UENV_INCLUDE_'* ]] || fail "sensor support was reduced"
+for target in Heltec_t096_repeater_lora_ota_no_external_sensors Heltec_t1_repeater_lora_ota_no_external_sensors; do
+  PIO_ENV_PLATFORM_BY_NAME[$target]=NRF52_PLATFORM
+  PLATFORMIO_BUILD_FLAGS=''
+  PLATFORMIO_BUILD_UNFLAGS=''
+  apply_repeater_neighbor_capacity "$target"
+  apply_nrf52_size_profile "$target"
+  [[ "$PLATFORMIO_BUILD_FLAGS" == *'-DMAX_NEIGHBOURS=50'* ]] || fail "$target omitted RAM-safe neighbours"
+  [[ "$PLATFORMIO_BUILD_FLAGS" == *'-DFLOOD_PACKET_FILTER_SLOTS=16'* ]] || fail "$target omitted RAM-safe rule table"
+  [[ "$PLATFORMIO_BUILD_FLAGS" != *'MESH_MIN_RUNTIME_HEAP'* ]] || fail "runtime RAM guard was overridden"
+done
+for target in Heltec_t096_companion_radio_full_femon RAK_4631_repeater; do
+  PIO_ENV_PLATFORM_BY_NAME[$target]=NRF52_PLATFORM
+  PLATFORMIO_BUILD_FLAGS=''
+  PLATFORMIO_BUILD_UNFLAGS=''
+  apply_nrf52_size_profile "$target"
+  [[ "$PLATFORMIO_BUILD_FLAGS" != *'FLOOD_PACKET_FILTER_SLOTS'* ]] || fail "$target received unrelated table reductions"
+  [[ "$PLATFORMIO_BUILD_FLAGS" != *'MAX_NEIGHBOURS'* ]] || fail "$target received unrelated neighbour reductions"
+done
+PIO_ENV_PLATFORM_BY_NAME[Heltec_v4_repeater]=ESP32_PLATFORM
+PLATFORMIO_BUILD_FLAGS=''
+apply_nrf52_size_profile Heltec_v4_repeater
+[ -z "$PLATFORMIO_BUILD_FLAGS" ] || fail "nRF52 policy changed an ESP32 target"
+echo 'Build-size diagnostics and constrained nRF52 recipes passed.'