Merge pull request #1904 from ruvnet/codex/firmware-delivery-20260911

fix(firmware): restore native C6 onboarding delivery

.github/workflows/firmware-ci.yml

@@ -204,3 +204,35 @@ jobs:
           idf.py build
           test "$(stat -c%s build/esp32-csi-node.bin)" -le $((1152 * 1024))
           strings build/esp32-csi-node.bin | grep -F "external U.FL"
+
+  publish-release-assets:
+    name: Publish firmware release assets
+    if: github.ref_type == 'tag'
+    needs: [version-guard, build, build-c6-idf6]
+    runs-on: ubuntu-latest
+    permissions:
+      contents: write
+    steps:
+      - name: Download the exact-run firmware artifacts
+        uses: actions/download-artifact@d3f86a106a0bac45b974a628896c90dbdf5c8093
+        with:
+          pattern: esp32-csi-node-firmware-*
+          path: release-downloads
+
+      - name: Package variants without filename collisions
+        run: |
+          mkdir -p release-assets
+          for directory in release-downloads/esp32-csi-node-firmware-*; do
+            variant="${directory##*/}"
+            tar -C "$directory" -czf "release-assets/${variant}.tar.gz" .
+          done
+          (cd release-assets && sha256sum *.tar.gz > SHA256SUMS.txt)
+
+      - name: Publish the downloadable firmware bundles
+        uses: softprops/action-gh-release@3bb12739c298aeb8a4eeaf626c5b8d85266b0e65
+        with:
+          name: ESP32 firmware ${{ github.ref_name }}
+          body: |
+            Exact-run ESP32-S3 8 MB, ESP32-S3 4 MB, and ESP32-C6 4 MB firmware bundles.
+            Verify each archive against `SHA256SUMS.txt` before flashing.
+          files: release-assets/*

firmware/esp32-csi-node/README.md

@@ -362,6 +362,14 @@ The `MSYS_NO_PATHCONV=1` prefix prevents Git Bash from mangling the `/project` p
 - `build/partition_table/partition-table.bin` -- flash partition layout
 - `build/esp32-csi-node.bin` -- application firmware
 
+### Release bundles
+
+Firmware downloads are published from dedicated `vX.Y.Z-esp32` tags after all
+S3 and C6 matrix builds pass. Each release contains separate S3 8 MB, S3 4 MB,
+and C6 4 MB archives plus an archive checksum manifest. The repository's
+automated `vNNNN` server releases (for example `v2655`) are not firmware tags;
+do not use their presence or absence of assets as firmware provenance.
+
 ### Custom Configuration
 
 To change Kconfig settings before building:

firmware/esp32-csi-node/main/serial_onboarding.c

@@ -162,16 +162,9 @@ static void serial_onboarding_task(void *argument)
     (void)argument;
     const int original_flags = fcntl(STDIN_FILENO, F_GETFL, 0);
     if (original_flags >= 0) (void)fcntl(STDIN_FILENO, F_SETFL, original_flags | O_NONBLOCK);
-    /* ESP-IDF secondary consoles mirror output but deliberately do not forward
-     * input to STDIN. Native S3/C6 USB Serial/JTAG therefore needs a bounded
-     * direct VFS reader while UART-console boards continue to use STDIN. */
-    const int usb_fd = open("/dev/secondary", O_RDONLY | O_NONBLOCK);
     char primary_line[ONBOARDING_LINE_MAX];
-    char usb_line[ONBOARDING_LINE_MAX];
     size_t primary_length = 0;
-    size_t usb_length = 0;
     bool primary_overflow = false;
-    bool usb_overflow = false;
     for (;;) {
         uint8_t input[64];
         const ssize_t count = read(STDIN_FILENO, input, sizeof(input));
@@ -182,12 +175,6 @@ static void serial_onboarding_task(void *argument)
             ESP_LOGW(TAG, "serial input unavailable: errno=%d", errno);
             vTaskDelay(pdMS_TO_TICKS(500));
         }
-        if (usb_fd >= 0) {
-            const ssize_t usb_count = read(usb_fd, input, sizeof(input));
-            if (usb_count > 0) {
-                consume_bytes(input, usb_count, usb_line, &usb_length, &usb_overflow);
-            }
-        }
         vTaskDelay(pdMS_TO_TICKS(20));
     }
 }

firmware/esp32-csi-node/release_bins/c6-onboarding/SHA256SUMS.txt

@@ -1,4 +1,4 @@
-126a4b9f305e207aa2e0db93caf09e27f77b3bee4b4f618a0cb963f10a4364bc  bootloader.bin
-183c4557a93f6f0be1680f45988b7c7320130c8e0ed5d9c900add038d5cc84fb  esp32-csi-node.bin
+12e9fe5bd0533c3eb8ebb1cc36f775668cc4dd39f334ea65e26529b87211dc4c  bootloader.bin
+baff3940ede0ce1658f2f5c3ba458cc9007753eb1519231d67b1ffa724382824  esp32-csi-node.bin
 7d2c7ac4888bfd75cd5f56e8d61f69595121183afc81556c876732fd3782c62f  ota_data_initial.bin
 4c2cc4ffd52641e23b779bd57b3908014083ac3c1aab395756478c89e70d81f0  partition-table.bin

firmware/esp32-csi-node/sdkconfig.defaults.esp32c6

@@ -19,6 +19,12 @@ CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions_4mb.csv"
 CONFIG_ESPTOOLPY_FLASHSIZE_4MB=y
 CONFIG_ESPTOOLPY_FLASHSIZE="4MB"
 
+# Native USB/JTAG is the interactive onboarding console on C6 boards. ESP-IDF
+# secondary consoles mirror output only and cannot receive RUVIEW_HELLO_V1.
+CONFIG_ESP_CONSOLE_USB_SERIAL_JTAG=y
+# CONFIG_ESP_CONSOLE_UART_DEFAULT is not set
+# CONFIG_ESP_CONSOLE_SECONDARY_USB_SERIAL_JTAG is not set
+
 # ── CSI (required) ──
 CONFIG_ESP_WIFI_CSI_ENABLED=y
 

firmware/esp32-csi-node/test/Makefile

@@ -55,7 +55,8 @@ FUZZ_JOBS     ?= 1
 .PHONY: all clean run_serialize run_edge run_nvs run_all test_adr110 run_adr110 \
         test_vitals run_vitals test_mmwave_detect run_mmwave_detect host_tests \
         test_thermal run_thermal test_csi_sanitize run_csi_sanitize \
-        test_c6_antenna run_c6_antenna test_serial_onboarding run_serial_onboarding
+        test_c6_antenna run_c6_antenna test_serial_onboarding run_serial_onboarding \
+        run_delivery_contract
 
 all: fuzz_serialize fuzz_edge fuzz_nvs test_adr110 test_vitals test_mmwave_detect \
      test_thermal test_csi_sanitize test_c6_antenna test_serial_onboarding
@@ -132,9 +133,12 @@ test_serial_onboarding: test_serial_onboarding_protocol.c $(MAIN_DIR)/serial_onb
 run_serial_onboarding: test_serial_onboarding
 	./test_serial_onboarding
 
+run_delivery_contract:
+	python3 test_delivery_contract.py
+
 host_tests: run_adr110 run_vitals run_mmwave_detect run_thermal run_csi_sanitize \
-            run_c6_antenna run_serial_onboarding
-	@echo "Host tests passed (ADR-110 + CSI sanitation + vitals + mmwave + thermal + C6 antenna + USB onboarding)"
+            run_c6_antenna run_serial_onboarding run_delivery_contract
+	@echo "Host tests passed (ADR-110 + CSI sanitation + vitals + mmwave + thermal + C6 antenna + USB onboarding + delivery contract)"
 
 # --- Serialize fuzzer ---
 # Tests csi_serialize_frame() with random wifi_csi_info_t inputs.

firmware/esp32-csi-node/test/test_delivery_contract.py

@@ -0,0 +1,37 @@
+#!/usr/bin/env python3
+"""Static delivery contracts that do not require an ESP-IDF toolchain."""
+
+from pathlib import Path
+import unittest
+
+
+FIRMWARE_ROOT = Path(__file__).resolve().parents[1]
+REPOSITORY_ROOT = FIRMWARE_ROOT.parents[1]
+
+
+class FirmwareDeliveryContractTests(unittest.TestCase):
+    def test_c6_uses_native_usb_serial_jtag_as_primary_console(self) -> None:
+        config = (FIRMWARE_ROOT / "sdkconfig.defaults.esp32c6").read_text()
+        self.assertIn("CONFIG_ESP_CONSOLE_USB_SERIAL_JTAG=y", config)
+        self.assertNotIn("CONFIG_ESP_CONSOLE_SECONDARY_USB_SERIAL_JTAG=y", config)
+
+        onboarding = (FIRMWARE_ROOT / "main/serial_onboarding.c").read_text()
+        self.assertNotIn('open("/dev/secondary"', onboarding)
+
+    def test_tracked_c6_onboarding_app_matches_version_txt(self) -> None:
+        expected = (FIRMWARE_ROOT / "version.txt").read_text().strip().encode()
+        app = (FIRMWARE_ROOT / "release_bins/c6-onboarding/esp32-csi-node.bin").read_bytes()
+        self.assertTrue(
+            expected + b"\0" in app,
+            f"tracked C6 app does not embed version {expected.decode()}",
+        )
+
+    def test_firmware_tags_publish_downloadable_release_assets(self) -> None:
+        workflow = (REPOSITORY_ROOT / ".github/workflows/firmware-ci.yml").read_text()
+        self.assertIn("publish-release-assets:", workflow)
+        self.assertIn("esp32-csi-node-firmware-*", workflow)
+        self.assertIn("softprops/action-gh-release@", workflow)
+
+
+if __name__ == "__main__":
+    unittest.main()