Merge pull request 'SD shutdown handling non-blocking' (#753) from sd-shutdown-non-blocking into main

Reviewed-on: #753
Reviewed-by: Marius Eggert <eggertm@irs.uni-stuttgart.de>

CHANGELOG.md

@@ -24,6 +24,8 @@ will consitute of a breaking change warranting a new major release:
 - Re-ordered some functions of the core controller in the initialize function.
 - Rad sensor is now only polled every 30 minutes instead of every device cycle to reduce wear of
   the RADFET electronics.
+- The SD cards will still be switched OFF on a reboot, but this is done in a non-blocking manner
+  now with a timeout of 10 seconds where the reboot will be performed in any case.
 - ACS Controller now includes the safe mode from FLP, which will calculate its rotational rate
   from SUS and MGM measurements. To accommodate these changes, low-pass filters for SUS
   measurements and rates as well as MGM measurements and rates are included. Usage of the new
@@ -45,6 +47,9 @@ will consitute of a breaking change warranting a new major release:
 
 ## Fixed
 
+- General bugs in the SD card state machine. This might fix some other known bugs for certain
+  combinations of switching ON and OFF SD cards and also makes the whole state machine a lot more
+  robust against hanging up.
 - SUS dummy handler went to `MODE_NORMAL` for ON commands.
 - PL PCDU dummy went to `MODE_NORMAL` for ON commands.
 

bsp_q7s/core/CoreController.cpp

@@ -554,21 +554,24 @@ ReturnValue_t CoreController::sdStateMachine() {
   }
 
   // This lambda checks the non-blocking operation of the SD card manager and assigns the new
-  // state on success. It returns true for an operation success and false otherwise
+  // state on success. It returns 0 for an operation success, -1 for failed operations, and 1
+  // for pending operations
   auto nonBlockingSdcOpChecking = [&](SdStates newStateOnSuccess, uint16_t maxCycleCount,
                                       std::string opPrintout) {
     SdCardManager::OpStatus status = sdcMan->checkCurrentOp(operation);
-    if (status == SdCardManager::OpStatus::SUCCESS) {
+    if (status == SdCardManager::OpStatus::SUCCESS or sdInfo.cycleCount > maxCycleCount) {
       sdFsmState = newStateOnSuccess;
       sdInfo.commandPending = false;
+      if (sdInfo.cycleCount > maxCycleCount) {
+        sif::warning << "CoreController::sdStateMachine: " << opPrintout << " takes too long"
+                     << std::endl;
+        sdInfo.cycleCount = 0;
+        return -1;
+      }
       sdInfo.cycleCount = 0;
-      return true;
+      return 0;
-    } else if (sdInfo.cycleCount > 4) {
+    };
-      sif::warning << "CoreController::sdStateMachine: " << opPrintout << " takes too long"
+    return 1;
-                   << std::endl;
-      return false;
-    }
-    return false;
   };
 
   if (sdFsmState == SdStates::UPDATE_SD_INFO_START) {
@@ -644,7 +647,7 @@ ReturnValue_t CoreController::sdStateMachine() {
         sdFsmState = tgtState;
       }
     } else {
-      if (nonBlockingSdcOpChecking(SdStates::MOUNT_SELF, 10, "Setting SDC state")) {
+      if (nonBlockingSdcOpChecking(SdStates::MOUNT_SELF, 10, "Setting SDC state") <= 0) {
         sdInfo.activeState = sd::SdState::ON;
         currentStateSetter(sdInfo.active, sd::SdState::ON);
         // Skip the two cycles now.
@@ -672,7 +675,7 @@ ReturnValue_t CoreController::sdStateMachine() {
       result = sdCardSetup(sdInfo.active, sd::SdState::MOUNTED, sdInfo.activeChar);
       sdInfo.commandPending = true;
     } else {
-      if (nonBlockingSdcOpChecking(SdStates::DETERMINE_OTHER, 5, "Mounting SD card")) {
+      if (nonBlockingSdcOpChecking(SdStates::DETERMINE_OTHER, 5, "Mounting SD card") <= 0) {
         sdcMan->setActiveSdCard(sdInfo.active);
         currMntPrefix = sdcMan->getCurrentMountPrefix();
         sdInfo.activeState = sd::SdState::MOUNTED;
@@ -714,12 +717,7 @@ ReturnValue_t CoreController::sdStateMachine() {
         sdInfo.commandPending = true;
       } else {
         if (nonBlockingSdcOpChecking(SdStates::SKIP_CYCLE_BEFORE_INFO_UPDATE, 10,
-                                     "Switching off other SD card")) {
+                                     "Switching off other SD card") <= 0) {
-          sdInfo.otherState = sd::SdState::OFF;
-          currentStateSetter(sdInfo.other, sd::SdState::OFF);
-        } else {
-          // Continue.. avoid being stuck here..
-          sdFsmState = SdStates::SKIP_CYCLE_BEFORE_INFO_UPDATE;
           sdInfo.otherState = sd::SdState::OFF;
           currentStateSetter(sdInfo.other, sd::SdState::OFF);
         }
@@ -730,12 +728,7 @@ ReturnValue_t CoreController::sdStateMachine() {
         sdInfo.commandPending = true;
       } else {
         if (nonBlockingSdcOpChecking(SdStates::MOUNT_UNMOUNT_OTHER, 10,
-                                     "Switching on other SD card")) {
+                                     "Switching on other SD card") <= 0) {
-          sdInfo.otherState = sd::SdState::ON;
-          currentStateSetter(sdInfo.other, sd::SdState::ON);
-        } else {
-          // Contnue.. avoid being stuck here.
-          sdFsmState = SdStates::MOUNT_UNMOUNT_OTHER;
           sdInfo.otherState = sd::SdState::ON;
           currentStateSetter(sdInfo.other, sd::SdState::ON);
         }
@@ -750,7 +743,8 @@ ReturnValue_t CoreController::sdStateMachine() {
         result = sdCardSetup(sdInfo.other, sd::SdState::ON, sdInfo.otherChar);
         sdInfo.commandPending = true;
       } else {
-        if (nonBlockingSdcOpChecking(SdStates::SET_STATE_OTHER, 10, "Unmounting other SD card")) {
+        if (nonBlockingSdcOpChecking(SdStates::SET_STATE_OTHER, 10, "Unmounting other SD card") <=
+            0) {
           sdInfo.otherState = sd::SdState::ON;
           currentStateSetter(sdInfo.other, sd::SdState::ON);
         } else {
@@ -764,7 +758,8 @@ ReturnValue_t CoreController::sdStateMachine() {
         result = sdCardSetup(sdInfo.other, sd::SdState::MOUNTED, sdInfo.otherChar);
         sdInfo.commandPending = true;
       } else {
-        if (nonBlockingSdcOpChecking(SdStates::UPDATE_SD_INFO_END, 4, "Mounting other SD card")) {
+        if (nonBlockingSdcOpChecking(SdStates::UPDATE_SD_INFO_END, 4, "Mounting other SD card") <=
+            0) {
           sdInfo.otherState = sd::SdState::MOUNTED;
           currentStateSetter(sdInfo.other, sd::SdState::MOUNTED);
         }
@@ -840,7 +835,7 @@ ReturnValue_t CoreController::sdCardSetup(sd::SdCard sdCard, sd::SdState targetS
   if (state == sd::SdState::MOUNTED) {
     if (targetState == sd::SdState::OFF) {
       sif::info << "Switching off SD card " << sdChar << std::endl;
-      return sdcMan->switchOffSdCard(sdCard, true, &sdInfo.currentState);
+      return sdcMan->switchOffSdCard(sdCard, sdInfo.currentState, true);
     } else if (targetState == sd::SdState::ON) {
       sif::info << "Unmounting SD card " << sdChar << std::endl;
       return sdcMan->unmountSdCard(sdCard);
@@ -874,7 +869,7 @@ ReturnValue_t CoreController::sdCardSetup(sd::SdCard sdCard, sd::SdState targetS
       return sdcMan->mountSdCard(sdCard);
     } else if (targetState == sd::SdState::OFF) {
       sif::info << "Switching off SD card " << sdChar << std::endl;
-      return sdcMan->switchOffSdCard(sdCard, false, &sdInfo.currentState);
+      return sdcMan->switchOffSdCard(sdCard, sdInfo.currentState, false);
     }
   } else {
     sif::warning << "CoreController::sdCardSetup: Invalid state for this call" << std::endl;
@@ -898,8 +893,7 @@ ReturnValue_t CoreController::sdColdRedundantBlockingInit() {
     sif::info << "Switching off secondary SD card " << sdInfo.otherChar << std::endl;
     // Switch off other SD card in cold redundant mode if setting up preferred one worked
     // without issues
-    ReturnValue_t result2 =
+    ReturnValue_t result2 = sdcMan->switchOffSdCard(sdInfo.other, sdInfo.currentState, true);
-        sdcMan->switchOffSdCard(sdInfo.other, sdInfo.otherState, &sdInfo.currentState);
     if (result2 != returnvalue::OK and result2 != SdCardManager::ALREADY_OFF) {
       sif::warning << "Switching off secondary SD card " << sdInfo.otherChar
                    << " in cold redundant mode failed" << std::endl;
@@ -1229,18 +1223,27 @@ ReturnValue_t CoreController::gracefulShutdownTasks(xsc::Chip chip, xsc::Copy co
   // Ensure that all writes/reads do finish.
   sync();
 
-  // Attempt graceful shutdown by unmounting and switching off SD cards
+  // Unmount and switch off SD cards. This could possibly fix issues with the SD card and is
-  sdcMan->switchOffSdCard(sd::SdCard::SLOT_0);
+  // the more graceful way to reboot the system. This function takes around 400 ms.
-  sdcMan->switchOffSdCard(sd::SdCard::SLOT_1);
+  ReturnValue_t result = handleSwitchingSdCardsOffNonBlocking();
+  if (result != returnvalue::OK) {
+    sif::error
+        << "CoreController::gracefulShutdownTasks: Issues unmounting or switching SD cards off"
+        << std::endl;
+  }
+
   // If any boot copies are unprotected.
   // Actually this function only ensures that reboots to the own image are protected..
-  ReturnValue_t result = setBootCopyProtection(xsc::Chip::SELF_CHIP, xsc::Copy::SELF_COPY, true,
+  result = setBootCopyProtection(xsc::Chip::SELF_CHIP, xsc::Copy::SELF_COPY, true, protOpPerformed,
-                                               protOpPerformed, false);
+                                 false);
   if (result == returnvalue::OK and protOpPerformed) {
     // TODO: Would be nice to notify operator. But we can't use the filesystem anymore
     // and a reboot is imminent. Use scratch buffer?
     sif::info << "Running slot was writeprotected before reboot" << std::endl;
   }
+  sif::info << "Graceful shutdown handling done" << std::endl;
+  // Ensure that all diagnostic prinouts arrive.
+  TaskFactory::delayTask(50);
   return result;
 }
 
@@ -2583,6 +2586,57 @@ void CoreController::announceSdInfo(SdCardManager::SdStatePair sdStates) {
   triggerEvent(core::ACTIVE_SD_INFO, p1, p2);
 }
 
+ReturnValue_t CoreController::handleSwitchingSdCardsOffNonBlocking() {
+  sdcMan->setBlocking(false);
+  SdCardManager::Operations op;
+  std::pair<sd::SdState, sd::SdState> sdStatus;
+  ReturnValue_t result = sdcMan->getSdCardsStatus(sdStatus);
+  if (result != returnvalue::OK) {
+    return result;
+  }
+  Countdown maxWaitTimeCd(10000);
+  // Stopwatch watch;
+  auto waitingForFinish = [&]() {
+    auto currentState = sdcMan->checkCurrentOp(op);
+    if (currentState == SdCardManager::OpStatus::IDLE) {
+      return returnvalue::OK;
+    }
+    while (currentState == SdCardManager::OpStatus::ONGOING) {
+      if (maxWaitTimeCd.hasTimedOut()) {
+        return returnvalue::FAILED;
+      }
+      TaskFactory::delayTask(50);
+      currentState = sdcMan->checkCurrentOp(op);
+    }
+    return returnvalue::OK;
+  };
+  if (sdStatus.first != sd::SdState::OFF) {
+    sdcMan->unmountSdCard(sd::SdCard::SLOT_0);
+    result = waitingForFinish();
+    if (result != returnvalue::OK) {
+      return result;
+    }
+    sdcMan->switchOffSdCard(sd::SdCard::SLOT_0, sdStatus, false);
+    result = waitingForFinish();
+    if (result != returnvalue::OK) {
+      return result;
+    }
+  }
+  if (sdStatus.second != sd::SdState::OFF) {
+    sdcMan->unmountSdCard(sd::SdCard::SLOT_1);
+    result = waitingForFinish();
+    if (result != returnvalue::OK) {
+      return result;
+    }
+    sdcMan->switchOffSdCard(sd::SdCard::SLOT_1, sdStatus, false);
+    result = waitingForFinish();
+    if (result != returnvalue::OK) {
+      return result;
+    }
+  }
+  return result;
+}
+
 bool CoreController::isNumber(const std::string &s) {
   return !s.empty() && std::find_if(s.begin(), s.end(),
                                     [](unsigned char c) { return !std::isdigit(c); }) == s.end();

bsp_q7s/core/CoreController.h

@@ -374,6 +374,7 @@ class CoreController : public ExtendedControllerBase, public ReceivesParameterMe
   ReturnValue_t gracefulShutdownTasks(xsc::Chip chip, xsc::Copy copy, bool& protOpPerformed);
 
   ReturnValue_t handleProtInfoUpdateLine(std::string nextLine);
+  ReturnValue_t handleSwitchingSdCardsOffNonBlocking();
   int handleBootCopyProtAtIndex(xsc::Chip targetChip, xsc::Copy targetCopy, bool protect,
                                 bool& protOperationPerformed, bool selfChip, bool selfCopy,
                                 bool allChips, bool allCopies, uint8_t arrIdx);

bsp_q7s/fs/SdCardManager.cpp

@@ -125,13 +125,8 @@ ReturnValue_t SdCardManager::switchOnSdCard(sd::SdCard sdCard, bool doMountSdCar
   return mountSdCard(sdCard);
 }
 
-ReturnValue_t SdCardManager::switchOffSdCard(sd::SdCard sdCard, bool doUnmountSdCard,
+ReturnValue_t SdCardManager::switchOffSdCard(sd::SdCard sdCard, SdStatePair& sdStates,
-                                             SdStatePair* statusPair) {
+                                             bool doUnmountSdCard) {
-  std::pair<sd::SdState, sd::SdState> active;
-  ReturnValue_t result = getSdCardsStatus(active);
-  if (result != returnvalue::OK) {
-    return result;
-  }
   if (doUnmountSdCard) {
     if (not blocking) {
       sif::warning << "SdCardManager::switchOffSdCard: Two-step command but manager is"
@@ -147,17 +142,17 @@ ReturnValue_t SdCardManager::switchOffSdCard(sd::SdCard sdCard, bool doUnmountSd
     return returnvalue::FAILED;
   }
   if (sdCard == sd::SdCard::SLOT_0) {
-    if (active.first == sd::SdState::OFF) {
+    if (sdStates.first == sd::SdState::OFF) {
       return ALREADY_OFF;
     }
   } else if (sdCard == sd::SdCard::SLOT_1) {
-    if (active.second == sd::SdState::OFF) {
+    if (sdStates.second == sd::SdState::OFF) {
       return ALREADY_OFF;
     }
   }
 
   if (doUnmountSdCard) {
-    result = unmountSdCard(sdCard);
+    ReturnValue_t result = unmountSdCard(sdCard);
     if (result != returnvalue::OK) {
       return result;
     }
@@ -189,7 +184,7 @@ ReturnValue_t SdCardManager::setSdCardState(sd::SdCard sdCard, bool on) {
   command << "q7hw sd set " << sdstring << " " << statestring;
   cmdExecutor.load(command.str(), blocking, printCmdOutput);
   ReturnValue_t result = cmdExecutor.execute();
-  if (blocking and result != returnvalue::OK) {
+  if (result != returnvalue::OK) {
     utility::handleSystemError(cmdExecutor.getLastError(), "SdCardManager::setSdCardState");
   }
   return result;
@@ -204,6 +199,7 @@ ReturnValue_t SdCardManager::getSdCardsStatus(SdStatePair& sdStates) {
 ReturnValue_t SdCardManager::mountSdCard(sd::SdCard sdCard) {
   using namespace std;
   if (cmdExecutor.getCurrentState() == CommandExecutor::States::PENDING) {
+    sif::warning << "SdCardManager::mountSdCard: Command still pending" << std::endl;
     return CommandExecutor::COMMAND_PENDING;
   }
   if (sdCard == sd::SdCard::BOTH) {

bsp_q7s/fs/SdCardManager.h

@@ -114,8 +114,7 @@ class SdCardManager : public SystemObject, public SdCardMountedIF {
    * @return - returnvalue::OK on success, ALREADY_ON if it is already on,
    *           SYSTEM_CALL_ERROR on system error
    */
-  ReturnValue_t switchOffSdCard(sd::SdCard sdCard, bool doUnmountSdCard = true,
+  ReturnValue_t switchOffSdCard(sd::SdCard sdCard, SdStatePair& sdStates, bool doUnmountSdCard);
-                                SdStatePair* statusPair = nullptr);
 
   /**
    * Get the state of the SD cards. If the state file does not exist, this function will