Size baseline

.github/workflows/ci-cd.yml

@@ -45,13 +45,56 @@ jobs:
         run: |
           pip install --upgrade platformio
           pip install gcovr==7.2
-          sudo apt-get install build-essential
+          sudo apt-get install build-essential bc jq
 
       - name: Run unit tests (native)
         run: pio test -e native -f test_ota_simple -f test_wifi_simple -f test_utils_simple -f test_constants_simple
 
       - name: Compile project
-        run: pio run
+        run: pio run -e ttgo-lora32-v1-release
+
+      - name: Check flash size limit
+        run: |
+          # Get build output and extract flash usage
+          pio run -e ttgo-lora32-v1-release 2>&1 | tee build_output.log
+
+          # Extract flash usage from build output
+          FLASH_USED=$(grep -oP 'Flash:.*used \K\d+' build_output.log | tail -n 1)
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "⚠️  Warning: Could not extract flash usage from build output"
+            echo "Looking for alternative patterns..."
+            # Try alternative patterns
+            FLASH_USED=$(grep -oP 'used \K\d+' build_output.log | tail -n 1)
+          fi
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "❌ ERROR: Could not determine flash usage from build output"
+            echo "Build output (last 20 lines):"
+            tail -n 20 build_output.log
+            exit 1
+          fi
+
+          echo "Flash used: $FLASH_USED bytes"
+
+          # Check if flash usage exceeds 1,300,000 bytes
+          if [ "$FLASH_USED" -gt 1300000 ]; then
+            echo "❌ ERROR: Flash usage ($FLASH_USED bytes) exceeds limit of 1,300,000 bytes"
+            echo "Flash usage: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+            exit 1
+          else
+            echo "✅ Flash usage OK: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+          fi
+
+      - name: Store map files as artifacts
+        uses: actions/upload-artifact@v4
+        with:
+          name: build-artifacts-branch-${{ github.sha }}
+          path: |
+            .pio/build/ttgo-lora32-v1-release/firmware.map
+            .pio/build/ttgo-lora32-v1-release/firmware.elf
+          retention-days: 30
+        if: always()
 
       - name: Generate Compilation DB
         run: pio run -t compiledb
@@ -104,13 +147,56 @@ jobs:
         run: |
           pip install --upgrade platformio
           pip install gcovr==7.2
-          sudo apt-get install build-essential
+          sudo apt-get install build-essential bc jq
 
       - name: Run unit tests (native)
         run: pio test -e native -f test_ota_simple -f test_wifi_simple -f test_utils_simple -f test_constants_simple
 
       - name: Compile project
-        run: pio run
+        run: pio run -e ttgo-lora32-v1-release
+
+      - name: Check flash size limit
+        run: |
+          # Get build output and extract flash usage
+          pio run -e ttgo-lora32-v1-release 2>&1 | tee build_output.log
+
+          # Extract flash usage from build output
+          FLASH_USED=$(grep -oP 'Flash:.*used \K\d+' build_output.log | tail -n 1)
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "⚠️  Warning: Could not extract flash usage from build output"
+            echo "Looking for alternative patterns..."
+            # Try alternative patterns
+            FLASH_USED=$(grep -oP 'used \K\d+' build_output.log | tail -n 1)
+          fi
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "❌ ERROR: Could not determine flash usage from build output"
+            echo "Build output (last 20 lines):"
+            tail -n 20 build_output.log
+            exit 1
+          fi
+
+          echo "Flash used: $FLASH_USED bytes"
+
+          # Check if flash usage exceeds 1,300,000 bytes
+          if [ "$FLASH_USED" -gt 1300000 ]; then
+            echo "❌ ERROR: Flash usage ($FLASH_USED bytes) exceeds limit of 1,300,000 bytes"
+            echo "Flash usage: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+            exit 1
+          else
+            echo "✅ Flash usage OK: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+          fi
+
+      - name: Store map files as artifacts
+        uses: actions/upload-artifact@v4
+        with:
+          name: build-artifacts-main-${{ github.sha }}
+          path: |
+            .pio/build/ttgo-lora32-v1-release/firmware.map
+            .pio/build/ttgo-lora32-v1-release/firmware.elf
+          retention-days: 30
+        if: always()
 
       - name: Generate Compilation DB
         run: pio run -t compiledb
@@ -195,20 +281,54 @@ jobs:
       - name: Install dependencies
         run: |
           pip install --upgrade platformio
-          sudo apt-get install build-essential
+          sudo apt-get install build-essential bc jq
 
       - name: Run unit tests (native)
         run: pio test -e native -f test_ota_simple -f test_wifi_simple -f test_utils_simple -f test_constants_simple
 
       - name: Compile with updated firmware version
-        run: pio run
+        run: pio run -e ttgo-lora32-v1-release
+
+      - name: Check flash size limit
+        run: |
+          # Get build output and extract flash usage
+          pio run -e ttgo-lora32-v1-release 2>&1 | tee build_output.log
+
+          # Extract flash usage from build output
+          FLASH_USED=$(grep -oP 'Flash:.*used \K\d+' build_output.log | tail -n 1)
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "⚠️  Warning: Could not extract flash usage from build output"
+            echo "Looking for alternative patterns..."
+            # Try alternative patterns
+            FLASH_USED=$(grep -oP 'used \K\d+' build_output.log | tail -n 1)
+          fi
+
+          if [ -z "$FLASH_USED" ]; then
+            echo "❌ ERROR: Could not determine flash usage from build output"
+            echo "Build output (last 20 lines):"
+            tail -n 20 build_output.log
+            exit 1
+          fi
+
+          echo "Flash used: $FLASH_USED bytes"
+
+          # Check if flash usage exceeds 1,300,000 bytes
+          if [ "$FLASH_USED" -gt 1300000 ]; then
+            echo "❌ ERROR: Flash usage ($FLASH_USED bytes) exceeds limit of 1,300,000 bytes"
+            echo "Flash usage: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+            exit 1
+          else
+            echo "✅ Flash usage OK: $FLASH_USED / 1,300,000 bytes ($(echo "scale=2; $FLASH_USED * 100 / 1300000" | bc)%)"
+          fi
 
       - name: Create release artifacts
         run: |
           mkdir -p artifacts
-          cp .pio/build/ttgo-lora32-v1/firmware.bin artifacts/firmware-${{ steps.validate-tag.outputs.tag_name }}.bin
-          cp .pio/build/ttgo-lora32-v1/firmware.elf artifacts/firmware-${{ steps.validate-tag.outputs.tag_name }}.elf
-          cp .pio/build/ttgo-lora32-v1/partitions.bin artifacts/partitions-${{ steps.validate-tag.outputs.tag_name }}.bin
+          cp .pio/build/ttgo-lora32-v1-release/firmware.bin artifacts/firmware-${{ steps.validate-tag.outputs.tag_name }}.bin
+          cp .pio/build/ttgo-lora32-v1-release/firmware.elf artifacts/firmware-${{ steps.validate-tag.outputs.tag_name }}.elf
+          cp .pio/build/ttgo-lora32-v1-release/firmware.map artifacts/firmware-${{ steps.validate-tag.outputs.tag_name }}.map
+          cp .pio/build/ttgo-lora32-v1-release/partitions.bin artifacts/partitions-${{ steps.validate-tag.outputs.tag_name }}.bin
 
           # Create a manifest file with build info
           cat > artifacts/build-info-${{ steps.validate-tag.outputs.tag_name }}.json << EOF
@@ -248,6 +368,7 @@ jobs:
             ### Artifacts
             - `firmware-${{ steps.validate-tag.outputs.tag_name }}.bin` - Binary firmware file
             - `firmware-${{ steps.validate-tag.outputs.tag_name }}.elf` - ELF debug file
+            - `firmware-${{ steps.validate-tag.outputs.tag_name }}.map` - Memory map file (for debugging memory regressions)
             - `partitions-${{ steps.validate-tag.outputs.tag_name }}.bin` - Partition table
             - `build-info-${{ steps.validate-tag.outputs.tag_name }}.json` - Build metadata
 

.github/workflows/size-baseline.yml

@@ -0,0 +1,168 @@
+name: Size Baseline Capture
+
+on:
+  push:
+    branches:
+      - size-baseline
+
+env:
+  PLATFORMIO_CACHE_DIR: ~/.platformio/.cache
+
+jobs:
+  capture-size-baseline:
+    name: Capture Size Baseline Artifacts
+    runs-on: ubuntu-latest
+    steps:
+      - name: Checkout code
+        uses: actions/checkout@v4
+
+      - name: Setup Python
+        uses: actions/setup-python@v4
+        with:
+          python-version: "3.9"
+
+      - name: Cache PlatformIO
+        uses: actions/cache@v3
+        with:
+          path: |
+            ~/.cache/pip
+            ${{ env.PLATFORMIO_CACHE_DIR }}
+          key: ${{ runner.os }}-pio-${{ hashFiles('platformio.ini') }}
+          restore-keys: |
+            ${{ runner.os }}-pio-
+
+      - name: Install dependencies
+        run: |
+          pip install --upgrade platformio
+          sudo apt-get install build-essential
+
+      - name: Build release and capture artifacts
+        run: |
+          # Clean build with verbose output - use release environment for size baseline
+          pio run -e ttgo-lora32-v1-release -v > ci-build-release.log 2>&1 || RELEASE_BUILD_FAILED=1
+
+          # Create baseline artifacts directory
+          mkdir -p ci-baseline-artifacts
+
+          # Copy build log first (always available)
+          cp ci-build-release.log ci-baseline-artifacts/
+
+          # Copy generated files if they exist
+          if [ -f ".pio/build/ttgo-lora32-v1-release/firmware.elf" ]; then
+            cp .pio/build/ttgo-lora32-v1-release/firmware.elf ci-baseline-artifacts/release-firmware.elf
+          else
+            echo "WARNING: release firmware.elf not found" >> ci-baseline-artifacts/build-warnings.txt
+          fi
+
+          if [ -f ".pio/build/ttgo-lora32-v1-release/firmware.map" ]; then
+            cp .pio/build/ttgo-lora32-v1-release/firmware.map ci-baseline-artifacts/release-firmware.map
+          else
+            echo "WARNING: release firmware.map not found" >> ci-baseline-artifacts/build-warnings.txt
+          fi
+
+          # Extract memory usage information
+          echo "Size Baseline - CI Build" > ci-baseline-artifacts/ci-memory-usage.txt
+          echo "========================" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "Build Environment: ubuntu-latest (GitHub Actions)" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "Build Date: $(date -u +%Y-%m-%dT%H:%M:%SZ)" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "Git Branch: ${{ github.ref_name }}" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "Git Commit: ${{ github.sha }}" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "" >> ci-baseline-artifacts/ci-memory-usage.txt
+
+          # Extract RAM and Flash usage from build log
+          echo "RELEASE BUILD (ttgo-lora32-v1-release):" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "========================================" >> ci-baseline-artifacts/ci-memory-usage.txt
+          if grep -q "RAM:\|Flash:" ci-build-release.log; then
+            grep -A 2 -B 2 "RAM:\|Flash:" ci-build-release.log >> ci-baseline-artifacts/ci-memory-usage.txt
+          else
+            echo "WARNING: No memory usage information found in release build log" >> ci-baseline-artifacts/ci-memory-usage.txt
+          fi
+
+          # Record release build status
+          if [ "$RELEASE_BUILD_FAILED" = "1" ]; then
+            echo "RELEASE BUILD STATUS: FAILED" >> ci-baseline-artifacts/ci-memory-usage.txt
+            echo "Release build failed - artifacts may be incomplete" >> ci-baseline-artifacts/build-warnings.txt
+          else
+            echo "RELEASE BUILD STATUS: SUCCESS" >> ci-baseline-artifacts/ci-memory-usage.txt
+          fi
+
+          echo "" >> ci-baseline-artifacts/ci-memory-usage.txt
+
+      - name: Build debug and capture artifacts
+        run: |
+          # Build debug environment for comparison
+          pio run -e ttgo-lora32-v1-debug -v > ci-build-debug.log 2>&1 || DEBUG_BUILD_FAILED=1
+
+          # Copy debug build log
+          cp ci-build-debug.log ci-baseline-artifacts/
+
+          # Copy debug generated files if they exist
+          if [ -f ".pio/build/ttgo-lora32-v1-debug/firmware.elf" ]; then
+            cp .pio/build/ttgo-lora32-v1-debug/firmware.elf ci-baseline-artifacts/debug-firmware.elf
+          else
+            echo "WARNING: debug firmware.elf not found" >> ci-baseline-artifacts/build-warnings.txt
+          fi
+
+          if [ -f ".pio/build/ttgo-lora32-v1-debug/firmware.map" ]; then
+            cp .pio/build/ttgo-lora32-v1-debug/firmware.map ci-baseline-artifacts/debug-firmware.map
+          else
+            echo "WARNING: debug firmware.map not found" >> ci-baseline-artifacts/build-warnings.txt
+          fi
+
+          # Add debug build info to memory usage report
+          echo "DEBUG BUILD (ttgo-lora32-v1-debug):" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "====================================" >> ci-baseline-artifacts/ci-memory-usage.txt
+          if grep -q "RAM:\|Flash:" ci-build-debug.log; then
+            grep -A 2 -B 2 "RAM:\|Flash:" ci-build-debug.log >> ci-baseline-artifacts/ci-memory-usage.txt
+          else
+            echo "WARNING: No memory usage information found in debug build log" >> ci-baseline-artifacts/ci-memory-usage.txt
+          fi
+
+          # Record debug build status
+          if [ "$DEBUG_BUILD_FAILED" = "1" ]; then
+            echo "DEBUG BUILD STATUS: FAILED" >> ci-baseline-artifacts/ci-memory-usage.txt
+            echo "Debug build failed - artifacts may be incomplete" >> ci-baseline-artifacts/build-warnings.txt
+          else
+            echo "DEBUG BUILD STATUS: SUCCESS" >> ci-baseline-artifacts/ci-memory-usage.txt
+          fi
+
+          echo "" >> ci-baseline-artifacts/ci-memory-usage.txt
+          echo "ARTIFACT FILES:" >> ci-baseline-artifacts/ci-memory-usage.txt
+          ls -la ci-baseline-artifacts/ >> ci-baseline-artifacts/ci-memory-usage.txt
+
+      - name: Upload CI baseline artifacts
+        uses: actions/upload-artifact@v4
+        if: always()
+        with:
+          name: ci-size-baseline-${{ github.sha }}
+          path: ci-baseline-artifacts/
+          retention-days: 90
+
+      - name: Display memory usage summary
+        run: |
+          echo "=== CI BUILD MEMORY USAGE SUMMARY ==="
+          echo "" 
+          echo "--- RELEASE BUILD ---"
+          if [ -f "ci-build-release.log" ]; then
+            grep -A 10 -B 5 "RAM:\|Flash:" ci-build-release.log || echo "Memory usage information not found in release build log"
+          else
+            echo "Release build log not found"
+          fi
+          echo ""
+          echo "--- DEBUG BUILD ---"
+          if [ -f "ci-build-debug.log" ]; then
+            grep -A 10 -B 5 "RAM:\|Flash:" ci-build-debug.log || echo "Memory usage information not found in debug build log"
+          else
+            echo "Debug build log not found"
+          fi
+          echo ""
+          echo "=== ARTIFACT FILES ==="
+          ls -la ci-baseline-artifacts/
+          echo ""
+          echo "=== WARNINGS (if any) ==="
+          if [ -f "ci-baseline-artifacts/build-warnings.txt" ]; then
+            cat ci-baseline-artifacts/build-warnings.txt
+          else
+            echo "No warnings found"
+          fi

Makefile

@@ -14,6 +14,16 @@ program:
 uploadfs:
 	platformio -f -c vim run --target uploadfs
 
+# Build the optimized release firmware
+.PHONY: release
+release:
+	platformio -f -c vim run -e ttgo-lora32-v1-release
+
+# Build and immediately upload the release firmware
+.PHONY: upload-release
+upload-release: release
+	platformio -f -c vim run -e ttgo-lora32-v1-release --target upload
+
 .PHONY: test
 test:
 	platformio test -e native