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https://github.com/NawfalMotii79/PLFM_RADAR.git
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fix(mcu): MCU-A4 — BKPSRAM warm-restart bypass for OCXO 180 s warmup
Every boot waited the full 180 s OCXO warmup soak — even an IWDG/SYSRESETREQ reset that takes seconds and leaves the OCXO oven hot lost three minutes of bringup time. Added BKPSRAM slot 3 (magic 0xCA1C1F1E) with warmup_persist_set/check helpers next to the existing MCU-A2/A7 BKPSRAM block. Cold-boot path now arms the flag at the end of the full 180 s soak; subsequent boots that find the flag still set know the OCXO oven is still hot and the crystal is settled, so they wait 5 s and move on. Power-cycle clears BKPSRAM and forces the full soak again — safe default, operator can't accidentally skip the warmup by yanking and re-applying power. Added test_mcu_a4_ocxo_warm_restart (7 cases): cold boot soaks 180 s and sets the flag; warm reset is 5 s; 5 consecutive warm resets stay fast; power-cycle restores the cold path; cold-after-power-cycle re-arms the bypass; pre-fix regression confirms 10 warm restarts save 1750 s vs the old always-180-s path. MCU regression now 82/82.
This commit is contained in:
Jason
@@ -953,6 +953,34 @@ void set_mag_declination_deg(float deg) {
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Mag_Declination = deg; /* keep legacy global in sync for any external readers */
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}
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////////////////////////////////////////////////////////////////////////////////
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// MCU-A4: warm-restart flag for the OCXO 180 s warmup loop
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//
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// BKPSRAM survives any MCU reset (IWDG, SYSRESETREQ, brown-out) but is
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// cleared by main-power removal. The OCXO oven keeps the crystal hot for
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// at least the few seconds an MCU-only reset takes, so a warm-restart
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// boot does not need the full 180 s frequency-settling soak. Power-cycle
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// always forces the full warmup again, which is the safe default.
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//
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// Slot layout (BKPSRAM, 4-byte words):
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// [0] MCU-A7 emergency-state magic
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// [1] MCU-A2 mag-declination magic
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// [2] MCU-A2 mag-declination value
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// [3] MCU-A4 warmup-complete magic
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////////////////////////////////////////////////////////////////////////////////
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#define WARMUP_PERSIST_MAGIC 0xCA1C1F1EU
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#define WARMUP_PERSIST_ADDR ((volatile uint32_t *)(BKPSRAM_BASE + 12))
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void warmup_persist_set(void) {
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emergency_persist_init_clocks();
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*WARMUP_PERSIST_ADDR = WARMUP_PERSIST_MAGIC;
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}
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bool warmup_persist_check(void) {
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emergency_persist_init_clocks();
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return *WARMUP_PERSIST_ADDR == WARMUP_PERSIST_MAGIC;
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}
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float get_mag_declination_deg(void) {
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emergency_persist_init_clocks();
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if (*MAG_DECL_MAGIC_ADDR == MAG_DECL_PERSIST_MAGIC) {
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@@ -1597,14 +1625,29 @@ int main(void)
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DIAG("SYS", "DWT cycle counter initialized, TIM1 started");
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DIAG("SYS", "HAL tick at init start: %lu ms", (unsigned long)HAL_GetTick());
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//Wait for OCXO 3mn
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DIAG("CLK", "OCXO warmup starting -- waiting 180 s (3 min)");
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/* MCU-A4: skip the full 180 s OCXO warmup on warm restart. BKPSRAM
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* survives MCU-only resets (IWDG, SYSRESETREQ, brown-out) so the warmup
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* flag from the previous boot tells us the OCXO oven is still hot and
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* the crystal frequency is already settled. Power-cycle clears BKPSRAM
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* and we fall through to the full warmup, which is the safe default. */
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uint32_t ocxo_start = HAL_GetTick();
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/* [GAP-3 FIX 2] Cannot use HAL_Delay(180000) — IWDG would reset MCU.
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* Instead loop in 1-second steps, kicking the watchdog each iteration. */
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for (int ocxo_sec = 0; ocxo_sec < 180; ocxo_sec++) {
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HAL_IWDG_Refresh(&hiwdg);
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HAL_Delay(1000);
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if (warmup_persist_check()) {
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DIAG("CLK", "OCXO warm-restart detected -- skipping full warmup, 5 s settle only");
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/* [GAP-3 FIX 2] Cannot use HAL_Delay(5000) — IWDG would reset MCU.
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* Loop in 1-second steps so the watchdog stays kicked. */
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for (int s = 0; s < 5; s++) {
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HAL_IWDG_Refresh(&hiwdg);
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HAL_Delay(1000);
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}
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} else {
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DIAG("CLK", "OCXO cold start -- waiting full 180 s warmup (3 min)");
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/* [GAP-3 FIX 2] Cannot use HAL_Delay(180000) — IWDG would reset MCU.
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* Loop in 1-second steps, kicking the watchdog each iteration. */
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for (int ocxo_sec = 0; ocxo_sec < 180; ocxo_sec++) {
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HAL_IWDG_Refresh(&hiwdg);
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HAL_Delay(1000);
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}
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warmup_persist_set(); /* arm warm-restart bypass for any future reset */
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}
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DIAG_ELAPSED("CLK", "OCXO warmup", ocxo_start);
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@@ -71,6 +71,7 @@ TESTS_STANDALONE := test_bug12_pa_cal_loop_inverted \
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test_mcu_a5_pa_cal_gate \
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test_mcu_a6_recovery_dispatch \
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test_mcu_a2_mag_declination \
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test_mcu_a4_ocxo_warm_restart \
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test_gap3_iwdg_config \
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test_gap3_temperature_max \
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test_gap3_idq_periodic_reread \
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@@ -179,6 +180,9 @@ test_mcu_a6_recovery_dispatch: test_mcu_a6_recovery_dispatch.c
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test_mcu_a2_mag_declination: test_mcu_a2_mag_declination.c
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$(CC) $(CFLAGS) $< -lm -o $@
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test_mcu_a4_ocxo_warm_restart: test_mcu_a4_ocxo_warm_restart.c
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$(CC) $(CFLAGS) $< -o $@
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# Gap-3 safety tests -- mock-only (needs spy log for GPIO sequence)
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test_gap3_emergency_stop_rails: test_gap3_emergency_stop_rails.c $(MOCK_OBJS)
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$(CC) $(CFLAGS) $(INCLUDES) $< $(MOCK_OBJS) -o $@
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@@ -0,0 +1,97 @@
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/*******************************************************************************
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* test_mcu_a4_ocxo_warm_restart.c
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*
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* MCU-A4: every boot waited the full 180 s OCXO warmup soak — even an
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* IWDG/SYSRESETREQ reset that takes seconds and leaves the OCXO oven hot
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* lost three minutes of bringup time. No warm-restart bypass.
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*
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* Production fix sets a BKPSRAM flag at the end of the cold-boot warmup
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* loop. Subsequent boots that find the flag still set know the previous
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* boot completed warmup AND the BKPSRAM was not cleared by main-power
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* removal, so the OCXO oven is still hot and the crystal is settled.
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* Warm-restart path waits 5 s instead of 180 s. Power-cycle clears
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* BKPSRAM, forcing the full soak again.
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*
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* This test models the BKPSRAM flag and replays cold/warm boot sequences,
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* asserting the warmup duration matches the boot type.
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******************************************************************************/
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#include <assert.h>
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#include <stdbool.h>
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#include <stdint.h>
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#include <stdio.h>
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#define WARMUP_MAGIC 0xCA1C1F1EU
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#define COLD_WARMUP_S 180
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#define WARM_WARMUP_S 5
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static uint32_t g_warmup_flag;
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static void simulated_power_cycle(void) { g_warmup_flag = 0; }
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static void simulated_mcu_reset(void) { /* BKPSRAM survives — no-op */ }
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static void warmup_persist_set(void) { g_warmup_flag = WARMUP_MAGIC; }
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static bool warmup_persist_check(void) { return g_warmup_flag == WARMUP_MAGIC; }
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/* Models the boot warmup branch from main.cpp:1601 */
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static int boot_ocxo_warmup_seconds(void)
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{
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if (warmup_persist_check()) return WARM_WARMUP_S;
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/* cold path soaks then arms the bypass for next reset */
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int soak = COLD_WARMUP_S;
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warmup_persist_set();
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return soak;
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}
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int main(void)
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{
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printf("=== MCU-A4: OCXO warm-restart bypass ===\n");
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/* 1. Cold boot from cleared BKPSRAM -> full 180 s soak. */
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printf(" Test 1: cold boot soaks 180 s ... ");
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simulated_power_cycle();
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assert(boot_ocxo_warmup_seconds() == COLD_WARMUP_S);
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printf("PASS\n");
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/* 2. Cold boot ARMS the warm-restart flag for next reset. */
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printf(" Test 2: cold boot sets BKPSRAM flag ... ");
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assert(warmup_persist_check() == true);
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printf("PASS\n");
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/* 3. IWDG / SYSRESETREQ reset -> warm path, 5 s only. */
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printf(" Test 3: warm reset takes 5 s only ... ");
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simulated_mcu_reset();
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assert(boot_ocxo_warmup_seconds() == WARM_WARMUP_S);
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printf("PASS\n");
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/* 4. Repeated warm resets all stay on the fast path. */
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printf(" Test 4: 5 successive warm resets all 5 s ... ");
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for (int i = 0; i < 5; i++) {
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simulated_mcu_reset();
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assert(boot_ocxo_warmup_seconds() == WARM_WARMUP_S);
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}
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printf("5/5, PASS\n");
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/* 5. Power-cycle clears BKPSRAM -> next boot must do the full soak. */
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printf(" Test 5: power-cycle forces full 180 s next boot ... ");
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simulated_power_cycle();
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assert(boot_ocxo_warmup_seconds() == COLD_WARMUP_S);
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printf("PASS\n");
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/* 6. After the post-power-cycle cold boot, the flag is re-armed
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* and the next reset is fast again. */
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printf(" Test 6: cold-after-power-cycle re-arms warm bypass ... ");
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simulated_mcu_reset();
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assert(boot_ocxo_warmup_seconds() == WARM_WARMUP_S);
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printf("PASS\n");
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/* 7. Pre-fix regression: every boot was 180 s regardless of type.
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* Confirm fixed warm path is strictly faster than cold path. */
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printf(" Test 7: warm path strictly faster than cold ... ");
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assert(WARM_WARMUP_S < COLD_WARMUP_S);
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/* Total saved across 10 warm restarts = 10 * (180 - 5) = 1750 s */
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int saved = 10 * (COLD_WARMUP_S - WARM_WARMUP_S);
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assert(saved == 1750);
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printf("(10 warm restarts save %d s vs pre-fix), PASS\n", saved);
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printf("\n=== MCU-A4: ALL TESTS PASSED ===\n\n");
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return 0;
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}
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