NexusPi Git Node
Commit 990649d8101952bebb9c3bc11eed62d05e534027
Parents : 8ee8e86
Author : James L <jrl290@gmail.com>
Date : 2026-02-25T13:48:10-05:00
Fix heap exhaustion: enable PSRAM allocator + bound all tables + auto-reboot watchdog
Root cause: heltec_V4_boundary build was missing -DRNS_USE_TLSF=1 and
-DRNS_USE_ALLOCATOR=1 flags, causing ALL C++ new/delete to use internal
SRAM (239KB) instead of the PSRAM-backed TLSF pool (~1.6MB). Transport
data structures consumed internal heap until WiFi driver could not
allocate RX buffers (ESP_ERR_NO_MEM).
Changes:
- platformio.ini: Add TLSF/allocator flags to heltec_V4_boundary env,
re-enable NDEBUG
- Transport.cpp: Add periodic culling of _path_requests (was unbounded,
grew one entry per unique destination forever). Cull entries older than
DESTINATION_TIMEOUT. Also cull _pending_local_path_requests for removed
interfaces, and fix missing .erase() (Python .pop() equivalent).
- RNode_Firmware.ino: Replace WiFi watchdog halt-serial with auto-reboot.
Add heap pressure check (reboot if free heap < 20KB). Increase WiFi
grace period from 5s to 15s. Remove orphaned boundary_done label.
Changes
3 files changed, 59 insertions(+), 37 deletions(-)
Diff
diff --git a/RNode_Firmware.ino b/RNode_Firmware.ino
index 8bcec68..ae070db 100755
--- a/RNode_Firmware.ino
+++ b/RNode_Firmware.ino
@@ -2229,19 +2229,26 @@ void loop() {
}
#ifdef BOUNDARY_MODE
- // ── WiFi disconnect watchdog ──────────────────────────────────────────────
- // When WiFi drops, dump diagnostic info and halt serial output so the
- // operator can read the last log lines over USB. The device keeps running
- // (LoRa repeater still works) but serial is frozen until reboot.
+ // ── Heap + WiFi watchdog ───────────────────────────────────────────────────
+ // Monitor heap and WiFi health. Auto-reboot on critical conditions:
+ // 1) Internal heap drops below 20KB (WiFi needs ~16KB for RX buffers)
+ // 2) WiFi down for >15s after having been connected (unrecoverable)
{
static bool _wifi_watchdog_armed = false; // armed once WiFi first connects
- static bool _wifi_watchdog_halted = false; // true = serial frozen
static uint32_t _wifi_lost_at = 0; // millis() when WiFi first lost
- static const uint32_t WIFI_GRACE_MS = 5000; // 5 s grace before halting
-
- if (_wifi_watchdog_halted) {
- // Frozen — skip all boundary work, just keep LoRa running
- goto boundary_done;
+ static const uint32_t WIFI_GRACE_MS = 15000; // 15s grace before reboot
+ static const uint32_t HEAP_CRITICAL = 20000; // 20KB minimum internal heap
+
+ // ── Heap pressure check (runs always) ─────────────────────────────────
+ uint32_t free_heap = ESP.getFreeHeap();
+ if (free_heap < HEAP_CRITICAL) {
+ Serial.printf("\r\n[WATCHDOG] CRITICAL: Free heap %u < %u — REBOOTING\r\n",
+ free_heap, HEAP_CRITICAL);
+ Serial.printf("[WATCHDOG] Min free: %u Max alloc: %u\r\n",
+ ESP.getMinFreeHeap(), ESP.getMaxAllocHeap());
+ Serial.flush();
+ delay(100);
+ ESP.restart();
}
bool wifi_now = wifi_is_connected();
@@ -2255,41 +2262,28 @@ void loop() {
if (_wifi_watchdog_armed && !wifi_now) {
if (_wifi_lost_at == 0) {
_wifi_lost_at = millis();
- Serial.printf("\r\n[WATCHDOG] WiFi connection LOST at %lu ms — grace period %lu ms\r\n",
+ Serial.printf("\r\n[WATCHDOG] WiFi lost at %lu ms (grace %lu ms)\r\n",
_wifi_lost_at, WIFI_GRACE_MS);
- Serial.printf("[WATCHDOG] WiFi.status() = %d RSSI = %d\r\n",
- (int)WiFi.status(), (int)WiFi.RSSI());
- Serial.printf("[WATCHDOG] Free heap: %u Min free heap: %u\r\n",
- ESP.getFreeHeap(), ESP.getMinFreeHeap());
- Serial.printf("[WATCHDOG] TCP backbone connected: %s clients: %d\r\n",
- (tcp_interface_ptr && tcp_interface_ptr->isConnected()) ? "yes" : "no",
- tcp_interface_ptr ? tcp_interface_ptr->clientCount() : 0);
- if (local_tcp_interface_ptr) {
- Serial.printf("[WATCHDOG] Local TCP connected: %s clients: %d\r\n",
- local_tcp_interface_ptr->isConnected() ? "yes" : "no",
- local_tcp_interface_ptr->clientCount());
- }
+ Serial.printf("[WATCHDOG] WiFi.status()=%d heap=%u min_heap=%u\r\n",
+ (int)WiFi.status(), free_heap, ESP.getMinFreeHeap());
Serial.flush();
}
- // Check if grace period expired
+ // Check if grace period expired — unrecoverable, reboot
if ((millis() - _wifi_lost_at) >= WIFI_GRACE_MS) {
- Serial.printf("\r\n[WATCHDOG] *** WiFi still down after %lu ms — HALTING SERIAL OUTPUT ***\r\n",
+ Serial.printf("\r\n[WATCHDOG] WiFi down %lu ms — REBOOTING\r\n",
millis() - _wifi_lost_at);
- Serial.printf("[WATCHDOG] WiFi.status() = %d RSSI = %d\r\n",
- (int)WiFi.status(), (int)WiFi.RSSI());
- Serial.printf("[WATCHDOG] Last boundary activity: %lu ms ago\r\n",
- millis() - boundary_state.last_bridge_activity);
- Serial.printf("[WATCHDOG] Packets bridged: LoRa→TCP=%lu TCP→LoRa=%lu\r\n",
+ Serial.printf("[WATCHDOG] WiFi.status()=%d heap=%u\r\n",
+ (int)WiFi.status(), ESP.getFreeHeap());
+ Serial.printf("[WATCHDOG] Bridged: L→T=%lu T→L=%lu\r\n",
boundary_state.packets_bridged_lora_to_tcp,
boundary_state.packets_bridged_tcp_to_lora);
- Serial.println("[WATCHDOG] Device still running (LoRa repeater active). Reboot to resume.");
Serial.flush();
- _wifi_watchdog_halted = true;
- goto boundary_done;
+ delay(100);
+ ESP.restart();
}
} else if (_wifi_watchdog_armed && wifi_now && _wifi_lost_at != 0) {
- // WiFi came back within grace period
- Serial.printf("[WATCHDOG] WiFi reconnected after %lu ms\r\n", millis() - _wifi_lost_at);
+ // WiFi recovered within grace period
+ Serial.printf("[WATCHDOG] WiFi back after %lu ms\r\n", millis() - _wifi_lost_at);
_wifi_lost_at = 0;
}
}
@@ -2318,7 +2312,6 @@ void loop() {
boundary_state.wifi_connected = wifi_is_connected();
}
-boundary_done:
#endif
#endif
diff --git a/lib/microReticulum/src/Transport.cpp b/lib/microReticulum/src/Transport.cpp
index 668309c..f9e0db6 100755
--- a/lib/microReticulum/src/Transport.cpp
+++ b/lib/microReticulum/src/Transport.cpp
@@ -571,6 +571,32 @@ static bool is_backbone_interface(const Interface& iface) {
}
}
+ // Cull the path requests table (entries older than destination timeout)
+ {
+ std::vector<Bytes> stale_path_requests;
+ for (const auto& [destination_hash, timestamp] : _path_requests) {
+ if (OS::time() > (timestamp + DESTINATION_TIMEOUT)) {
+ stale_path_requests.push_back(destination_hash);
+ }
+ }
+ for (const Bytes& destination_hash : stale_path_requests) {
+ _path_requests.erase(destination_hash);
+ }
+ }
+
+ // Cull pending local path requests for interfaces that no longer exist
+ {
+ std::vector<Bytes> stale_plpr;
+ for (const auto& [destination_hash, iface] : _pending_local_path_requests) {
+ if (_interfaces.count(iface.get_hash()) == 0) {
+ stale_plpr.push_back(destination_hash);
+ }
+ }
+ for (const Bytes& destination_hash : stale_plpr) {
+ _pending_local_path_requests.erase(destination_hash);
+ }
+ }
+
// Cull the tunnel table
count = 0;
std::vector<Bytes> stale_tunnels;
@@ -2144,6 +2170,7 @@ static bool is_backbone_interface(const Interface& iface) {
if (iter != _pending_local_path_requests.end()) {
//p desiring_interface = Transport.pending_local_path_requests.pop(packet.destination_hash)
//const Interface& desiring_interface = (*iter).second;
+ _pending_local_path_requests.erase(iter); // CBA FIX: pop() equivalent
retransmit_timeout = now;
retries = PATHFINDER_R;
diff --git a/platformio.ini b/platformio.ini
index 0f2d1e1..fc6b28e 100755
--- a/platformio.ini
+++ b/platformio.ini
@@ -342,7 +342,9 @@ build_flags =
-DARDUINO_USB_CDC_ON_BOOT=1
-DBOARD_HAS_PSRAM=1
-DBOUNDARY_MODE
- ;-DNDEBUG ; re-enable debug output for WiFi disconnect investigation
+ -DNDEBUG
+ -DRNS_USE_TLSF=1
+ -DRNS_USE_ALLOCATOR=1
; --- Boundary mode defaults (override via EEPROM at runtime) ---
; TCP server mode (0=server, 1=client)
-DBOUNDARY_TCP_MODE=0
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