Integrate ExpressLRS TX module support and its stacked ESP32 heap changes.
Use the approved Linkflow calibration (17-30 dBm), preserve the PA drive
and output path after radio recovery, and keep LoRa OTA enabled.
Preserve stored ACLs and filters on allocation failure, release owned
client/filter buffers, service heap OTA contexts on Companions, release
self-serving workspaces after TempRadio, and reset staged-resume state
when a context is released. Keep manual staging and active operations
alive. Account for all moved allocations in the runtime RAM gate.
Validation: 1,393 native cases; radio-power, heap-context, ACL persistence,
shared-queue transfer, display/inbox, radio receive, and memory regressions.
Firmware builds passed for Linkflow, Heltec V2 Companion, T-Beam MQTT
repeater, Heltec V4 R8 MQTT repeater, RAK4631 repeater, and Indicator Full.
Physical verification awaits access to the currently offline lab Pi.
Persist separate display modes and timeouts in seconds for battery and USB power, expose four controls in WebConfig and CLI, and apply one shared policy across display-equipped roles.
Detect R8 external power from a USB host or calibrated battery voltage above 4.21 V, with cached sampling and hysteresis. Add policy, persistence, browser, and R8 power-detection regression coverage.
Port the measured RXPS model without changing Cascade wire preambles or automatically enabling experimental levels. Use a spaced weighted median with bounded calibration windows, preserve packet ownership across CAD, and check actual SX126x receive mode before recovery.
Preserve Cascade sleep and radio fixes, integrate the new sensor and board profiles, and correct BSEC script inheritance and the MKE UART pin conflict. Native regressions, production-method/SPI harnesses, and ESP32, nRF52, and STM32 builds pass. Hardware comparison and fault-injection validation are recorded privately.
The variant carried a "classic ESP32 DRAM strip": MAX_CLIENTS cut from 32 to
2, the flood rule engine and group moderation compiled out, and the filter,
scope and moderation tables cut to a single slot each. All of it existed to
squeeze fixed .bss tables into classic ESP32's ~124 KiB static DRAM window.
Those tables now live on the heap, so the strip buys nothing. Removing it also
clears a real trap: with two client slots, once both held a protected manager
(admin, region manager or filter manager) putClient() could no longer allocate,
and every further admin login was refused with no reply to the operator.
Static DRAM with the full feature set restored:
70,764 / 124,580 occupied, 53,816 free (8,192 required)
An ExpressLRS 900 MHz transmitter module: ESP32-D0WDQ6, 4 MB flash, SX1276
driving an external PA through a DAC gain input on GPIO26.
Pin values come from the ExpressLRS hardware layout for this target
(Unified_ESP32_900_TX). The board brings out only RX_EN, so RadioLib's
single-pin RF switch handling covers it. Note GPIO12 is both RX_EN and the
MTDI flash-voltage strapping pin, so it must stay low through reset.
Verified on hardware: boots, radio initialises, TX power changes take
effect and are rejected outside the configured range, and the node repeats
flood traffic.
Uses dual_ota_1536k.csv, and 115200 for upload because the CH340 on this
board corrupts transfers above 230400.
Move OTA_HEAP_CONTEXT from two hand-edited envs to a pre-script gated on
build.mcu == "esp32", so every classic ESP32 image gets it and none can drift.
S2/S3/C-series and nRF52 keep the .bss singleton: they have no equivalent
static-DRAM ceiling, so there a guaranteed-present workspace is the better
trade for what is ultimately a recovery path. It has to be a build flag rather
than a header default, because OTA_HEAP_CONTEXT must hold the same value in
every translation unit that sees OtaContext.h - OtaContext.cpp included - and a
header test on CONFIG_IDF_TARGET_ESP32 would depend on include order relative
to sdkconfig.h. The script defers to OTA_SHARED_COMPANION_QUEUE where a Full
Companion recipe already owns the storage.
Fix a gap this exposes in the roles that now use it. Only CLI entry points
acquire the context, so once it was released, a repeater with the temporary
radio profile up would no longer serve or announce its own firmware - LoRa OTA
would look enabled and silently do nothing. ota_service_temp_radio_context()
holds the workspace for exactly the temp-radio window and hands it back
outside it, which is where the saving was coming from anyway. Wired into the
repeater, room server and sensor loops; the Companion keeps its own
acquire-on-host-demand policy, since its context is borrowed from the offline
message queue and must not be taken speculatively.
Static DRAM, classic ESP32 (bytes occupied of a 124,580 region):
Heltec_v2_repeater 108,332 -> 70,732
Heltec_v2_room_server 83,716 -> 68,300
Heltec_v2_companion_radio_ble 123,236 -> 107,772 (was failing on main)
Tbeam_SX1262_repeater 86,932 -> 71,468
Tbeam_SX1262_repeater_observer_mqtt 121,132 -> 83,532 (was failing)
Classic ESP32 links into a dram0_0_seg of only 124,580 bytes: memory.ld
carves the BT controller's 0xdb5c (56,156) reservation off the 0x2c200
window before the application gets any. Three large objects dominated what
was left, and Tbeam_SX1262_repeater_observer_mqtt overran the build's 8 KiB
static reserve by 4,744 bytes.
Heap-allocate them instead, each with a defined behaviour when the
allocation fails:
- OtaContext: generalize the Companion's borrowed-storage path behind
OTA_DYNAMIC_CONTEXT and add OTA_HEAP_CONTEXT, which allocates the context
on first use and frees it once no transfer, apply or folder link needs it.
A repeater is idle nearly all the time, so the workspace is usually absent.
Exhaustion is reported to the caller and the operation declines.
- ClientACL: the client table becomes a pointer with a live capacity;
capacity 0 refuses new clients rather than writing through a null table.
- MyMesh flood packet filters: likewise, with flood_packet_filter_slots as
the live bound for every rule loop. At capacity 0 the node forwards
unfiltered, and both save paths refuse to write so a stored ruleset is
never replaced by an empty file.
Also override the Arduino SDK's weak btInUse() in simple_repeater so
initArduino() releases the BT controller memory to the heap. That grows the
runtime heap these tables now come from; it cannot recover the same
reservation from the linker's static window.
Static DRAM, classic ESP32:
Heltec_v2_repeater 108,332 -> 70,732
Tbeam_SX1262_repeater_observer_mqtt 121,132 -> 83,532 (was failing)
Bind Companion replies to request transports, make dual-CDC USB sessions nonblocking and reconnect-safe, and harden nRF52 watchdog/OTA storage paths. Fix T096 button debounce, display wake, sleep races, and the compact message layout; add exact WisBlock OTA profiles plus expanded native/static/HIL documentation.
Reserve board-specific GPIOs, make ESP-NOW channel/format handling configurable, and coordinate WiFi, BLE, NTP, MQTT, and host actions safely.
Add the Indicator message page, exclusive transport selector, dynamic 480/320 rendering, larger transport typography, pairing cleanup, and corresponding tests and documentation.
Add durable TempRadio, ACL, clock, bridge, GPS/I2C, USB logging, and Indicator recovery safeguards together with expanded automation, build/profile contracts, release metadata, and the hardware validation ledger.
Add selectable shared ESP-NOW channels, raw/wrapped bridge compatibility, and bounded fragmentation for maximum-size packets.\n\nGive ESP32 Full profiles WiFi coexistence, stabilize WebConfig and USB terminal lifecycles, and keep disabled bridges stopped during observer updates.\n\nUpdate generated UI, firmware selection, documentation, and regression coverage.
Adapt the validated fan thermostat, battery ADC calibration, GPS baud, SX1262 register patch, and 1700us PA ramp behavior from mintylinux/Meshcore-T-beam-1W-Firmware to the current board architecture. Also make Arduino 3 full-build dependency switching reliable after standard ESP32 builds and guard the release hardware contract with regression coverage.
Add the framed BLE mOTA transport and companion control path, complete the full-profile build and runtime fixes, and document and test the OTA workflow.
mikecarper
MUSTARDTIGERFPV
Kevin Le
Liam Cottle
Scott Powell