Release v0.6.2-esp32: ADR-081 kernel + Timer Svc fix, 4MB CI variant

version.txt → 0.6.2.

firmware-ci.yml: matrix-build both 8MB (sdkconfig.defaults) and 4MB
(sdkconfig.defaults.4mb) variants, uploading variant-named artifacts
(esp32-csi-node.bin / esp32-csi-node-4mb.bin, partition-table.bin /
partition-table-4mb.bin). Unblocks 6-binary releases from CI alone,
no local ESP-IDF required.

CHANGELOG: promote [Unreleased] ADR-081 work into [v0.6.2-esp32],
plus Fixed entries for Timer Svc stack overflow and the
fast_loop_cb → emit_feature_state implicit-decl compile error.

Validation: 30 s run on ESP32-S3 (MAC 3c:0f:02:e9:b5:f8), 149
rv_feature_state emissions, no stack overflow, HEALTH mesh packet sent.

Co-Authored-By: claude-flow <ruv@ruv.net>

Author: ruvnet

.github/workflows/firmware-ci.yml

@@ -12,31 +12,50 @@ on:
 
 jobs:
   build:
-    name: Build ESP32-S3 Firmware
+    name: Build ESP32-S3 Firmware (${{ matrix.variant }})
     runs-on: ubuntu-latest
     container:
       image: espressif/idf:v5.4
+    strategy:
+      fail-fast: false
+      matrix:
+        include:
+          - variant: 8mb
+            sdkconfig: sdkconfig.defaults
+            partition_table_name: partitions_display.csv
+            size_limit_kb: 1100
+            artifact_app: esp32-csi-node.bin
+            artifact_pt: partition-table.bin
+          - variant: 4mb
+            sdkconfig: sdkconfig.defaults.4mb
+            partition_table_name: partitions_4mb.csv
+            size_limit_kb: 1100
+            artifact_app: esp32-csi-node-4mb.bin
+            artifact_pt: partition-table-4mb.bin
 
     steps:
       - uses: actions/checkout@v4
 
-      - name: Build firmware
+      - name: Build firmware (${{ matrix.variant }})
         working-directory: firmware/esp32-csi-node
         run: |
           . $IDF_PATH/export.sh
+          if [ "${{ matrix.variant }}" != "8mb" ]; then
+            cp "${{ matrix.sdkconfig }}" sdkconfig.defaults
+          fi
           idf.py set-target esp32s3
           idf.py build
 
-      - name: Verify binary size (< 1100 KB gate)
+      - name: Verify binary size (< ${{ matrix.size_limit_kb }} KB gate)
         working-directory: firmware/esp32-csi-node
         run: |
           BIN=build/esp32-csi-node.bin
           SIZE=$(stat -c%s "$BIN")
-          MAX=$((1100 * 1024))
+          MAX=$((${{ matrix.size_limit_kb }} * 1024))
           echo "Binary size: $SIZE bytes ($(( SIZE / 1024 )) KB)"
-          echo "Size limit:  $MAX bytes (1100 KB — includes WASM runtime + HTTP client for Seed swarm bridge)"
+          echo "Size limit:  $MAX bytes (${{ matrix.size_limit_kb }} KB)"
           if [ "$SIZE" -gt "$MAX" ]; then
-            echo "::error::Firmware binary exceeds 1100 KB size gate ($SIZE > $MAX)"
+            echo "::error::Firmware binary exceeds ${{ matrix.size_limit_kb }} KB size gate ($SIZE > $MAX)"
             exit 1
           fi
           echo "Binary size OK: $SIZE <= $MAX"
@@ -47,14 +66,11 @@ jobs:
           ERRORS=0
           BIN=build/esp32-csi-node.bin
 
-          # Check binary exists and is non-empty.
           if [ ! -s "$BIN" ]; then
             echo "::error::Binary not found or empty"
             exit 1
           fi
 
-          # Check partition table magic (0xAA50 at offset 0).
-          # Use od instead of xxd (xxd not available in espressif/idf container).
           PT=build/partition_table/partition-table.bin
           if [ -f "$PT" ]; then
             MAGIC=$(od -A n -t x1 -N 2 "$PT" | tr -d ' ')
@@ -64,14 +80,12 @@ jobs:
             fi
           fi
 
-          # Check bootloader exists.
           BL=build/bootloader/bootloader.bin
           if [ ! -s "$BL" ]; then
             echo "::warning::Bootloader binary missing or empty"
             ERRORS=$((ERRORS + 1))
           fi
 
-          # Verify non-zero data in binary (not all 0xFF padding).
           NONZERO=$(od -A n -t x1 -N 1024 "$BIN" | tr -d ' f\n' | wc -c)
           if [ "$NONZERO" -lt 100 ]; then
             echo "::error::Binary appears to be mostly padding (non-zero chars: $NONZERO)"
@@ -84,19 +98,27 @@ jobs:
             echo "Flash image integrity verified"
           fi
 
+      - name: Stage release binaries with variant-specific names
+        working-directory: firmware/esp32-csi-node
+        run: |
+          mkdir -p release-staging
+          cp build/esp32-csi-node.bin                      release-staging/${{ matrix.artifact_app }}
+          cp build/partition_table/partition-table.bin     release-staging/${{ matrix.artifact_pt }}
+          if [ "${{ matrix.variant }}" = "8mb" ]; then
+            cp build/bootloader/bootloader.bin             release-staging/bootloader.bin
+            cp build/ota_data_initial.bin                  release-staging/ota_data_initial.bin
+          fi
+          ls -la release-staging/
+
       - name: Check QEMU ESP32-S3 support status
         run: |
           echo "::notice::ESP32-S3 QEMU support is experimental in ESP-IDF v5.4. "
           echo "Full smoke testing requires QEMU 8.2+ with xtensa-esp32s3 target."
           echo "See: https://github.com/espressif/qemu/wiki"
 
-      - name: Upload firmware artifact
+      - name: Upload firmware artifact (${{ matrix.variant }})
         uses: actions/upload-artifact@v4
         with:
-          name: esp32-csi-node-firmware
-          path: |
-            firmware/esp32-csi-node/build/esp32-csi-node.bin
-            firmware/esp32-csi-node/build/bootloader/bootloader.bin
-            firmware/esp32-csi-node/build/partition_table/partition-table.bin
-            firmware/esp32-csi-node/build/ota_data_initial.bin
+          name: esp32-csi-node-firmware-${{ matrix.variant }}
+          path: firmware/esp32-csi-node/release-staging/
           retention-days: 90

CHANGELOG.md

@@ -7,6 +7,21 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 
 ## [Unreleased]
 
+## [v0.6.2-esp32] — 2026-04-20
+
+Firmware release cutting ADR-081 and the Timer Svc stack fix discovered during
+on-hardware validation. Cut from `main` at commit pointing to this entry.
+Tested on ESP32-S3 (QFN56 rev v0.2, MAC `3c:0f:02:e9:b5:f8`), 30 s continuous
+run: no crashes, 149 `rv_feature_state_t` emissions (~5 Hz), medium/slow ticks
+firing cleanly, HEALTH mesh packets sent.
+
+### Fixed
+- **Firmware: Timer Svc stack overflow on ADR-081 fast loop** — `emit_feature_state()` runs inside the FreeRTOS Timer Svc task via the fast-loop callback; it calls `stream_sender` network I/O which pushes past the ESP-IDF 2 KiB default timer stack and panics ~1 s after boot. Bumped `CONFIG_FREERTOS_TIMER_TASK_STACK_DEPTH` to 8 KiB in `sdkconfig.defaults`, `sdkconfig.defaults.template`, and `sdkconfig.defaults.4mb`. Follow-up (tracked separately): move heavy work out of the timer daemon into a dedicated worker task.
+- **Firmware: `adaptive_controller.c` implicit declaration** (#404) — `fast_loop_cb` called `emit_feature_state()` before its static definition, triggering `-Werror=implicit-function-declaration`. Added a forward declaration above the first use.
+
+### Changed
+- **CI: firmware build matrix (8MB + 4MB)** — `firmware-ci.yml` now matrix-builds both the default 8MB (`sdkconfig.defaults`) and 4MB SuperMini (`sdkconfig.defaults.4mb`) variants, uploading distinct artifacts and producing variant-named release binaries (`esp32-csi-node.bin` / `esp32-csi-node-4mb.bin`, `partition-table.bin` / `partition-table-4mb.bin`).
+
 ### Added
 - **ADR-081: Adaptive CSI Mesh Firmware Kernel** — New 5-layer architecture
   (Radio Abstraction Layer / Adaptive Controller / Mesh Sensing Plane /

firmware/esp32-csi-node/version.txt

@@ -1 +1 @@
-0.6.1
+0.6.2