Wifi update from sd

firmware/bootloader/openblt_chibios/openblt_net.cpp

@@ -1,6 +1,7 @@
 #include "pch.h"
 
 #include "wifi_socket.h"
+#include "wifi_sd_firmware_updater.h"
 #include "thread_controller.h"
 #include "socket/include/socket.h"
 
@@ -40,6 +41,10 @@ void NetDeferredInit() {
 
 	didInit = true;
 
+	// In the bootloader the SD-card WiFi firmware update never runs, so unblock
+	// WifiHelperThread (which waits on this semaphore before it calls initWifi()).
+	signalWifiSdUpdateComplete();
+
 	initWifi();
 
 	wifiInitFinisher.startThread();

firmware/console/binary_log/sd_file_log.cpp

@@ -243,7 +243,13 @@ static void sdTriggerLogger() {
 #endif /* EFI_TOOTH_LOGGER */
 }
 
-static THD_WORKING_AREA(sdCardLoggerStack, 3 * UTILITY_THREAD_STACK_SIZE); // MMC monitor thread
+#if EFI_WIFI
+// WiFi needs extra stack, as WiFi firmware update happens from here
+static THD_WORKING_AREA(sdCardLoggerStack, 6 * UTILITY_THREAD_STACK_SIZE);
+#else // not EFI_WIFI
+static THD_WORKING_AREA(sdCardLoggerStack, 4 * UTILITY_THREAD_STACK_SIZE);
+#endif
+
 static THD_FUNCTION(sdCardLoggerThread, arg) {
 	(void)arg;
 	chRegSetThreadName("MMC Card Logger");

firmware/ext/atwinc1500/spi_flash/source/spi_flash.cpp

@@ -687,7 +687,7 @@ sint8 spi_flash_erase(uint32 u32Offset, uint32 u32Sz)
 	uint32 t;
 	t = GetTickCount();
 #endif
-	M2M_PRINT("\r\n>Start erasing...\r\n");
+	M2M_INFO(">Start erasing...");
 	for(i = u32Offset; i < (u32Sz +u32Offset); i += (16*FLASH_PAGE_SZ))
 	{
 		ret += spi_flash_write_enable();
@@ -696,14 +696,15 @@ sint8 spi_flash_erase(uint32 u32Offset, uint32 u32Sz)
 		ret += spi_flash_read_status_reg(&tmp);
 		do
 		{
+			nm_bsp_sleep(10);
 			if(ret != M2M_SUCCESS) goto ERR;
 			ret += spi_flash_read_status_reg(&tmp);
 		}while(tmp & 0x01);
 
 	}
-	M2M_PRINT("Done\r\n");
+	M2M_INFO("Done!");
 #ifdef PROFILING
-	M2M_PRINT("#Erase time = %f sec\n", (GetTickCount()-t)/1000.0);
+	M2M_INFO("#Erase time = %f sec\n", (GetTickCount()-t)/1000.0);
 #endif
 ERR:
 	return ret;

firmware/hw_layer/mmc_card.h

@@ -11,6 +11,8 @@
 
 #include "buffered_writer.h"
 
+#include <array>
+
 BaseBlockDevice* initializeMmcBlockDevice();
 void stopMmcBlockDevice();
 
@@ -45,5 +47,6 @@ namespace sd_mem {
 FATFS* getFs();
 FIL* getLogFileFd();
 SdLogBufferWriter& getLogBuffer();
+std::array<uint8_t, 512>& getWifiUpdateBuffer();
 } // namespace sd_mem
 #endif // EFI_PROD_CODE

firmware/hw_layer/mmc_card_attach.cpp

@@ -36,13 +36,14 @@ struct {
 		FATFS fs;
 		FIL file;
 		SdLogBufferWriter logBuffer;
+		std::array<uint8_t, 512> wifiUpdateBuffer;
 	} usedPart;
 
-	static_assert(sizeof(usedPart) <= 2048);
+	static_assert(sizeof(usedPart) <= 4096);
 
 	// Fill the struct out to a full MPU region
-	uint8_t padding[2048 - sizeof(usedPart)];
-} mmcCardCacheControlledStorage SDMMC_MEMORY(2048);
+	uint8_t padding[4096 - sizeof(usedPart)];
+} mmcCardCacheControlledStorage SDMMC_MEMORY(4096);
 
 namespace sd_mem {
 FATFS* getFs() {
@@ -56,6 +57,10 @@ FIL* getLogFileFd() {
 SdLogBufferWriter& getLogBuffer() {
 	return mmcCardCacheControlledStorage.usedPart.logBuffer;
 }
+
+std::array<uint8_t, 512>& getWifiUpdateBuffer() {
+	return mmcCardCacheControlledStorage.usedPart.wifiUpdateBuffer;
+}
 } // namespace sd_mem
 
 #endif // !EFI_BOOTLOADER
@@ -132,8 +137,8 @@ BaseBlockDevice* initializeMmcBlockDevice() {
 #if defined(STM32H7XX) && !EFI_BOOTLOADER
 	{
 		void* base = &mmcCardCacheControlledStorage;
-		static_assert(sizeof(mmcCardCacheControlledStorage) == 2048);
-		uint32_t size = MPU_RASR_SIZE_2K;
+		static_assert(sizeof(mmcCardCacheControlledStorage) == 4096);
+		uint32_t size = MPU_RASR_SIZE_4K;
 
 		mpuConfigureRegion(
 				MPU_REGION_5,

firmware/hw_layer/mmc_card_mount.cpp

@@ -6,6 +6,11 @@
 
 #include "ff.h"
 #include "mass_storage_init.h"
+#include "usbconsole.h"
+
+#if EFI_WIFI
+#include "wifi_sd_firmware_updater.h"
+#endif
 
 static bool fs_ready = false;
 
@@ -18,6 +23,9 @@ void onUsbConnectedNotifyMmcI() {
 #endif /* HAL_USE_USB_MSD */
 
 bool mountSdFilesystem() {
+	Timer t;
+	t.reset();
+
 	auto cardBlockDevice = initializeMmcBlockDevice();
 
 #if EFI_TUNER_STUDIO
@@ -27,18 +35,45 @@ bool mountSdFilesystem() {
 
 	// if no card, don't try to mount FS
 	if (!cardBlockDevice) {
+#if EFI_WIFI
+		signalWifiSdUpdateComplete();
+#endif
+#if HAL_USE_USB_MSD
+		// No SD card - allow USB to enumerate so serial and INI drive still work
+		allowUsbEnumeration();
+#endif
 		return false;
 	}
 
+	// Mount filesystem temporarily for WiFi update check
+	bool mounted = f_mount(sd_mem::getFs(), "/", 1) == FR_OK;
+
+	if (mounted) {
+#if EFI_WIFI
+		// Check for WiFi firmware update/dump trigger files on SD card
+		tryUpdateWifiFirmwareFromSd();
+		tryDumpWifiFirmwareToSd();
+#endif
+		// Unmount — we'll either hand the card to USB or re-mount for logging
+		f_mount(nullptr, "/", 0);
+	} else {
+		efiPrintf("SD card failed to mount filesystem");
+	}
+
+#if EFI_WIFI
+	signalWifiSdUpdateComplete();
+#endif
+
 #if HAL_USE_USB_MSD
-	// Wait for the USB stack to wake up, or a 5 second timeout, whichever occurs first
+	// Allow USB to enumerate - the host will see the real SD card
+	allowUsbEnumeration();
+
+	// Wait for the USB enumeration, or a 5 second timeout, whichever occurs first
 	msg_t usbResult = usbConnectedSemaphore.wait(TIME_MS2I(5000));
 
 	bool hasUsb = usbResult == MSG_OK;
 
-	// If we have a device AND USB is connected, mount the card to USB, otherwise
-	// mount the null device and try to mount the filesystem ourselves
-	if (cardBlockDevice && hasUsb) {
+	if (hasUsb) {
 		// Mount the real card to USB
 		attachMsdSdCard(cardBlockDevice);
 

firmware/hw_layer/ports/stm32/serial_over_usb/usbconsole.cpp

@@ -16,6 +16,12 @@
 
 static bool isUsbSerialInitialized = false;
 
+#if HAL_USE_USB_MSD
+// When MSD is enabled, defer USB bus connection until the SD card thread
+// has finished any WiFi firmware updates and is ready to present media.
+static chibios_rt::BinarySemaphore usbEnumerationAllowed(/* taken =*/true);
+#endif
+
 /**
  * start USB serial using hard-coded communications pins (see comments inside the code)
  */
@@ -42,11 +48,23 @@ void usb_serial_start() {
 	chThdSleepMilliseconds(250);
 #endif /* EFI_SKIP_USB_DISCONNECT */
 	usbStart(serusbcfg.usbp, &usbcfg);
+
+#if HAL_USE_USB_MSD
+	// Wait for the SD card thread to signal that it's ready
+	usbEnumerationAllowed.wait();
+#endif
+
 	usbConnectBus(serusbcfg.usbp);
 
 	isUsbSerialInitialized = true;
 }
 
+void allowUsbEnumeration() {
+#if HAL_USE_USB_MSD
+	usbEnumerationAllowed.signal();
+#endif
+}
+
 bool is_usb_serial_ready() {
 	return isUsbSerialInitialized && SDU1.config->usbp->state == USB_ACTIVE;
 }

firmware/hw_layer/ports/stm32/serial_over_usb/usbconsole.h

@@ -7,13 +7,9 @@
 
 #pragma once
 
-#ifdef __cplusplus
-extern "C" {
-#endif /* __cplusplus */
+void usb_serial_start();
+bool is_usb_serial_ready();
 
-void usb_serial_start(void);
-bool is_usb_serial_ready(void);
-
-#ifdef __cplusplus
-}
-#endif /* __cplusplus */
+#if HAL_USE_USB_MSD
+void allowUsbEnumeration();
+#endif

firmware/net/net.mk

@@ -1,6 +1,6 @@
 ALLCPPSRC += \
 	$(PROJECT_DIR)/net/wifi_socket.cpp \
-	# $(PROJECT_DIR)/net/wifi_firmware_updater.cpp \
+	$(PROJECT_DIR)/net/wifi_sd_firmware_updater.cpp
 
 ALLINC += \
 	$(PROJECT_DIR)/net \