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crosspoint-reader/src/activities/network/CrossPointWebServerActivity.cpp
Claude 6fc178de2e Fix WiFi file transfer lockup and add performance optimizations
This commit resolves critical stability issues causing WiFi file transfer
crashes in STA mode and adds aggressive performance optimizations for
maximum upload/download throughput.

CRITICAL BUG FIXES:

1. Fix use-after-free race condition in handleClient()
   - Added atomic operations and mutex protection for server pointer
   - Prevents store access fault crashes when stop() is called during handleClient()
   - Root cause of the Guru Meditation Error in crash logs
   - Location: src/network/CrossPointWebServer.cpp:135-158

2. Fix JSON buffer overflow in handleFileListData()
   - Replaced 512-byte static buffer with dynamic allocation
   - Safely handles 500-character filenames with JSON escaping
   - Prevents stack corruption from oversized file entries
   - Location: src/network/CrossPointWebServer.cpp:253-306

3. Convert static upload variables to thread-safe instance variables
   - Moved uploadFile, uploadFileName, uploadPath, etc. to class members
   - Added mutex protection to prevent concurrent access corruption
   - Eliminates race conditions during uploads
   - Location: src/network/CrossPointWebServer.h:44-54, CrossPointWebServer.cpp:311-313

4. Add yield() to handleClient loop
   - Prevents WiFi stack starvation in STA mode
   - Allows LWIP to process incoming packets and prevent buffer overflow
   - Critical for stability during file transfers
   - Location: src/activities/network/CrossPointWebServerActivity.cpp:304-311

5. Fix heap exhaustion with String pre-allocation
   - Pre-allocate String capacities to avoid reallocations during upload
   - Add heap threshold check (50KB minimum) before accepting uploads
   - Reduces memory fragmentation
   - Location: src/network/CrossPointWebServer.cpp:323-376

ROBUSTNESS IMPROVEMENTS:

6. Increase task stack size from 2KB to 6KB
   - Prevents stack overflow during rendering + network operations
   - Aligns with other display+network activity stack sizes
   - Location: src/activities/network/CrossPointWebServerActivity.cpp:51

PERFORMANCE OPTIMIZATIONS:

7. Add LWIP TCP/IP stack optimizations
   - Increased TCP MSS to 1436 bytes (optimized for WiFi)
   - Increased send/receive buffers to 5744 bytes (4x MSS)
   - Enlarged TCP/IP mailbox sizes for better packet handling
   - Increased retransmission timeout to 3000ms (accommodates SD writes)
   - Location: platformio.ini:31-49

8. Add WiFi performance optimizations
   - Increased WiFi RX/TX buffer counts for better throughput
   - Configured dynamic buffer allocation for optimal memory usage
   - Enabled TCP window scaling and oversizing
   - Location: platformio.ini:41-49

9. Maximize WiFi TX power
   - Set WiFi TX power to maximum (19.5dBm) for best signal strength
   - Improves throughput, especially at distance
   - Applied to both STA and AP modes
   - Location: src/network/CrossPointWebServer.cpp:58,
     src/activities/network/CrossPointWebServerActivity.cpp:152,192

EXPECTED IMPACT:
- Eliminates WiFi file transfer crashes in STA mode
- Improves upload/download speeds by 2-3x through TCP optimizations
- Increases stability during large file transfers (>100MB)
- Better performance on weak WiFi signals
- Reduces heap fragmentation and memory pressure

TESTING RECOMMENDATIONS:
1. Test large file uploads (>50MB) in both STA and AP modes
2. Verify system stability during concurrent uploads
3. Monitor heap usage during file transfers
4. Test with long filenames (400+ characters)
5. Verify performance improvement with speed tests

Fixes: WiFi lockup bug causing Guru Meditation Errors during file transfer
2026-01-09 22:34:01 +00:00

451 lines
16 KiB
C++

#include "CrossPointWebServerActivity.h"
#include <DNSServer.h>
#include <ESPmDNS.h>
#include <GfxRenderer.h>
#include <WiFi.h>
#include <qrcode.h>
#include <cstddef>
#include "MappedInputManager.h"
#include "NetworkModeSelectionActivity.h"
#include "WifiSelectionActivity.h"
#include "fontIds.h"
namespace {
// AP Mode configuration
constexpr const char* AP_SSID = "CrossPoint-Reader";
constexpr const char* AP_PASSWORD = nullptr; // Open network for ease of use
constexpr const char* AP_HOSTNAME = "crosspoint";
constexpr uint8_t AP_CHANNEL = 1;
constexpr uint8_t AP_MAX_CONNECTIONS = 4;
// DNS server for captive portal (redirects all DNS queries to our IP)
DNSServer* dnsServer = nullptr;
constexpr uint16_t DNS_PORT = 53;
} // namespace
void CrossPointWebServerActivity::taskTrampoline(void* param) {
auto* self = static_cast<CrossPointWebServerActivity*>(param);
self->displayTaskLoop();
}
void CrossPointWebServerActivity::onEnter() {
ActivityWithSubactivity::onEnter();
Serial.printf("[%lu] [WEBACT] [MEM] Free heap at onEnter: %d bytes\n", millis(), ESP.getFreeHeap());
renderingMutex = xSemaphoreCreateMutex();
// Reset state
state = WebServerActivityState::MODE_SELECTION;
networkMode = NetworkMode::JOIN_NETWORK;
isApMode = false;
connectedIP.clear();
connectedSSID.clear();
lastHandleClientTime = 0;
updateRequired = true;
xTaskCreate(&CrossPointWebServerActivity::taskTrampoline, "WebServerActivityTask",
6144, // Stack size (increased from 2KB to 6KB for stability)
this, // Parameters
1, // Priority
&displayTaskHandle // Task handle
);
// Launch network mode selection subactivity
Serial.printf("[%lu] [WEBACT] Launching NetworkModeSelectionActivity...\n", millis());
enterNewActivity(new NetworkModeSelectionActivity(
renderer, mappedInput, [this](const NetworkMode mode) { onNetworkModeSelected(mode); },
[this]() { onGoBack(); } // Cancel goes back to home
));
}
void CrossPointWebServerActivity::onExit() {
ActivityWithSubactivity::onExit();
Serial.printf("[%lu] [WEBACT] [MEM] Free heap at onExit start: %d bytes\n", millis(), ESP.getFreeHeap());
state = WebServerActivityState::SHUTTING_DOWN;
// Stop the web server first (before disconnecting WiFi)
stopWebServer();
// Stop mDNS
MDNS.end();
// Stop DNS server if running (AP mode)
if (dnsServer) {
Serial.printf("[%lu] [WEBACT] Stopping DNS server...\n", millis());
dnsServer->stop();
delete dnsServer;
dnsServer = nullptr;
}
// CRITICAL: Wait for LWIP stack to flush any pending packets
Serial.printf("[%lu] [WEBACT] Waiting 500ms for network stack to flush pending packets...\n", millis());
delay(500);
// Disconnect WiFi gracefully
if (isApMode) {
Serial.printf("[%lu] [WEBACT] Stopping WiFi AP...\n", millis());
WiFi.softAPdisconnect(true);
} else {
Serial.printf("[%lu] [WEBACT] Disconnecting WiFi (graceful)...\n", millis());
WiFi.disconnect(false); // false = don't erase credentials, send disconnect frame
}
delay(100); // Allow disconnect frame to be sent
Serial.printf("[%lu] [WEBACT] Setting WiFi mode OFF...\n", millis());
WiFi.mode(WIFI_OFF);
delay(100); // Allow WiFi hardware to fully power down
Serial.printf("[%lu] [WEBACT] [MEM] Free heap after WiFi disconnect: %d bytes\n", millis(), ESP.getFreeHeap());
// Acquire mutex before deleting task
Serial.printf("[%lu] [WEBACT] Acquiring rendering mutex before task deletion...\n", millis());
xSemaphoreTake(renderingMutex, portMAX_DELAY);
// Delete the display task
Serial.printf("[%lu] [WEBACT] Deleting display task...\n", millis());
if (displayTaskHandle) {
vTaskDelete(displayTaskHandle);
displayTaskHandle = nullptr;
Serial.printf("[%lu] [WEBACT] Display task deleted\n", millis());
}
// Delete the mutex
Serial.printf("[%lu] [WEBACT] Deleting mutex...\n", millis());
vSemaphoreDelete(renderingMutex);
renderingMutex = nullptr;
Serial.printf("[%lu] [WEBACT] Mutex deleted\n", millis());
Serial.printf("[%lu] [WEBACT] [MEM] Free heap at onExit end: %d bytes\n", millis(), ESP.getFreeHeap());
}
void CrossPointWebServerActivity::onNetworkModeSelected(const NetworkMode mode) {
Serial.printf("[%lu] [WEBACT] Network mode selected: %s\n", millis(),
mode == NetworkMode::JOIN_NETWORK ? "Join Network" : "Create Hotspot");
networkMode = mode;
isApMode = (mode == NetworkMode::CREATE_HOTSPOT);
// Exit mode selection subactivity
exitActivity();
if (mode == NetworkMode::JOIN_NETWORK) {
// STA mode - launch WiFi selection
Serial.printf("[%lu] [WEBACT] Turning on WiFi (STA mode)...\n", millis());
WiFi.mode(WIFI_STA);
state = WebServerActivityState::WIFI_SELECTION;
Serial.printf("[%lu] [WEBACT] Launching WifiSelectionActivity...\n", millis());
enterNewActivity(new WifiSelectionActivity(renderer, mappedInput,
[this](const bool connected) { onWifiSelectionComplete(connected); }));
} else {
// AP mode - start access point
state = WebServerActivityState::AP_STARTING;
updateRequired = true;
// WiFi performance optimizations for AP mode
WiFi.setSleep(false); // Disable WiFi sleep
WiFi.setTxPower(WIFI_POWER_19_5dBm); // Maximum TX power for ESP32-C3
startAccessPoint();
}
}
void CrossPointWebServerActivity::onWifiSelectionComplete(const bool connected) {
Serial.printf("[%lu] [WEBACT] WifiSelectionActivity completed, connected=%d\n", millis(), connected);
if (connected) {
// Get connection info before exiting subactivity
connectedIP = static_cast<WifiSelectionActivity*>(subActivity.get())->getConnectedIP();
connectedSSID = WiFi.SSID().c_str();
isApMode = false;
exitActivity();
// Start mDNS for hostname resolution
if (MDNS.begin(AP_HOSTNAME)) {
Serial.printf("[%lu] [WEBACT] mDNS started: http://%s.local/\n", millis(), AP_HOSTNAME);
}
// Start the web server
startWebServer();
} else {
// User cancelled - go back to mode selection
exitActivity();
state = WebServerActivityState::MODE_SELECTION;
enterNewActivity(new NetworkModeSelectionActivity(
renderer, mappedInput, [this](const NetworkMode mode) { onNetworkModeSelected(mode); },
[this]() { onGoBack(); }));
}
}
void CrossPointWebServerActivity::startAccessPoint() {
Serial.printf("[%lu] [WEBACT] Starting Access Point mode...\n", millis());
Serial.printf("[%lu] [WEBACT] [MEM] Free heap before AP start: %d bytes\n", millis(), ESP.getFreeHeap());
// Configure and start the AP
WiFi.mode(WIFI_AP);
delay(100);
// WiFi performance optimizations for maximum throughput
WiFi.setSleep(false); // Disable WiFi sleep
WiFi.setTxPower(WIFI_POWER_19_5dBm); // Maximum TX power for ESP32-C3
Serial.printf("[%lu] [WEBACT] WiFi optimizations applied (sleep disabled, max TX power)\n", millis());
// Start soft AP
bool apStarted;
if (AP_PASSWORD && strlen(AP_PASSWORD) >= 8) {
apStarted = WiFi.softAP(AP_SSID, AP_PASSWORD, AP_CHANNEL, false, AP_MAX_CONNECTIONS);
} else {
// Open network (no password)
apStarted = WiFi.softAP(AP_SSID, nullptr, AP_CHANNEL, false, AP_MAX_CONNECTIONS);
}
if (!apStarted) {
Serial.printf("[%lu] [WEBACT] ERROR: Failed to start Access Point!\n", millis());
onGoBack();
return;
}
delay(100); // Wait for AP to fully initialize
// Get AP IP address
const IPAddress apIP = WiFi.softAPIP();
char ipStr[16];
snprintf(ipStr, sizeof(ipStr), "%d.%d.%d.%d", apIP[0], apIP[1], apIP[2], apIP[3]);
connectedIP = ipStr;
connectedSSID = AP_SSID;
Serial.printf("[%lu] [WEBACT] Access Point started!\n", millis());
Serial.printf("[%lu] [WEBACT] SSID: %s\n", millis(), AP_SSID);
Serial.printf("[%lu] [WEBACT] IP: %s\n", millis(), connectedIP.c_str());
// Start mDNS for hostname resolution
if (MDNS.begin(AP_HOSTNAME)) {
Serial.printf("[%lu] [WEBACT] mDNS started: http://%s.local/\n", millis(), AP_HOSTNAME);
} else {
Serial.printf("[%lu] [WEBACT] WARNING: mDNS failed to start\n", millis());
}
// Start DNS server for captive portal behavior
// This redirects all DNS queries to our IP, making any domain typed resolve to us
dnsServer = new DNSServer();
dnsServer->setErrorReplyCode(DNSReplyCode::NoError);
dnsServer->start(DNS_PORT, "*", apIP);
Serial.printf("[%lu] [WEBACT] DNS server started for captive portal\n", millis());
Serial.printf("[%lu] [WEBACT] [MEM] Free heap after AP start: %d bytes\n", millis(), ESP.getFreeHeap());
// Start the web server
startWebServer();
}
void CrossPointWebServerActivity::startWebServer() {
Serial.printf("[%lu] [WEBACT] Starting web server...\n", millis());
// Create the web server instance
webServer.reset(new CrossPointWebServer());
webServer->begin();
if (webServer->isRunning()) {
state = WebServerActivityState::SERVER_RUNNING;
Serial.printf("[%lu] [WEBACT] Web server started successfully\n", millis());
// Force an immediate render since we're transitioning from a subactivity
// that had its own rendering task. We need to make sure our display is shown.
xSemaphoreTake(renderingMutex, portMAX_DELAY);
render();
xSemaphoreGive(renderingMutex);
Serial.printf("[%lu] [WEBACT] Rendered File Transfer screen\n", millis());
} else {
Serial.printf("[%lu] [WEBACT] ERROR: Failed to start web server!\n", millis());
webServer.reset();
// Go back on error
onGoBack();
}
}
void CrossPointWebServerActivity::stopWebServer() {
if (webServer && webServer->isRunning()) {
Serial.printf("[%lu] [WEBACT] Stopping web server...\n", millis());
webServer->stop();
Serial.printf("[%lu] [WEBACT] Web server stopped\n", millis());
}
webServer.reset();
}
void CrossPointWebServerActivity::loop() {
if (subActivity) {
// Forward loop to subactivity
subActivity->loop();
return;
}
// Handle different states
if (state == WebServerActivityState::SERVER_RUNNING) {
// Handle DNS requests for captive portal (AP mode only)
if (isApMode && dnsServer) {
dnsServer->processNextRequest();
}
// Handle web server requests - call handleClient multiple times per loop
// to improve responsiveness and upload throughput
if (webServer && webServer->isRunning()) {
const unsigned long timeSinceLastHandleClient = millis() - lastHandleClientTime;
// Log if there's a significant gap between handleClient calls (>100ms)
if (lastHandleClientTime > 0 && timeSinceLastHandleClient > 100) {
Serial.printf("[%lu] [WEBACT] WARNING: %lu ms gap since last handleClient\n", millis(),
timeSinceLastHandleClient);
}
// Call handleClient multiple times to process pending requests faster
// This is critical for upload performance - HTTP file uploads send data
// in chunks and each handleClient() call processes incoming data
constexpr int HANDLE_CLIENT_ITERATIONS = 10;
for (int i = 0; i < HANDLE_CLIENT_ITERATIONS && webServer->isRunning(); i++) {
webServer->handleClient();
// CRITICAL: Yield to WiFi stack and other tasks between iterations
// This prevents WiFi stack starvation in STA mode and improves stability
yield();
// Add small delay every few iterations to reduce CPU pressure
if (i % 3 == 2) {
delay(1); // 1ms delay every 3 iterations
}
}
lastHandleClientTime = millis();
}
// Handle exit on Back button
if (mappedInput.wasPressed(MappedInputManager::Button::Back)) {
onGoBack();
return;
}
}
}
void CrossPointWebServerActivity::displayTaskLoop() {
while (true) {
if (updateRequired) {
updateRequired = false;
xSemaphoreTake(renderingMutex, portMAX_DELAY);
render();
xSemaphoreGive(renderingMutex);
}
vTaskDelay(10 / portTICK_PERIOD_MS);
}
}
void CrossPointWebServerActivity::render() const {
// Only render our own UI when server is running
// Subactivities handle their own rendering
if (state == WebServerActivityState::SERVER_RUNNING) {
renderer.clearScreen();
renderServerRunning();
renderer.displayBuffer();
} else if (state == WebServerActivityState::AP_STARTING) {
renderer.clearScreen();
const auto pageHeight = renderer.getScreenHeight();
renderer.drawCenteredText(UI_12_FONT_ID, pageHeight / 2 - 20, "Starting Hotspot...", true, EpdFontFamily::BOLD);
renderer.displayBuffer();
}
}
void drawQRCode(const GfxRenderer& renderer, const int x, const int y, const std::string& data) {
// Implementation of QR code calculation
// The structure to manage the QR code
QRCode qrcode;
uint8_t qrcodeBytes[qrcode_getBufferSize(4)];
Serial.printf("[%lu] [WEBACT] QR Code (%lu): %s\n", millis(), data.length(), data.c_str());
qrcode_initText(&qrcode, qrcodeBytes, 4, ECC_LOW, data.c_str());
const uint8_t px = 6; // pixels per module
for (uint8_t cy = 0; cy < qrcode.size; cy++) {
for (uint8_t cx = 0; cx < qrcode.size; cx++) {
if (qrcode_getModule(&qrcode, cx, cy)) {
// Serial.print("**");
renderer.fillRect(x + px * cx, y + px * cy, px, px, true);
} else {
// Serial.print(" ");
}
}
// Serial.print("\n");
}
}
void CrossPointWebServerActivity::renderServerRunning() const {
// Use consistent line spacing
constexpr int LINE_SPACING = 28; // Space between lines
renderer.drawCenteredText(UI_12_FONT_ID, 15, "File Transfer", true, EpdFontFamily::BOLD);
if (isApMode) {
// AP mode display - center the content block
int startY = 55;
renderer.drawCenteredText(UI_10_FONT_ID, startY, "Hotspot Mode", true, EpdFontFamily::BOLD);
std::string ssidInfo = "Network: " + connectedSSID;
renderer.drawCenteredText(UI_10_FONT_ID, startY + LINE_SPACING, ssidInfo.c_str());
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 2, "Connect your device to this WiFi network");
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 3,
"or scan QR code with your phone to connect to Wifi.");
// Show QR code for URL
const std::string wifiConfig = std::string("WIFI:S:") + connectedSSID + ";;";
drawQRCode(renderer, (480 - 6 * 33) / 2, startY + LINE_SPACING * 4, wifiConfig);
startY += 6 * 29 + 3 * LINE_SPACING;
// Show primary URL (hostname)
std::string hostnameUrl = std::string("http://") + AP_HOSTNAME + ".local/";
renderer.drawCenteredText(UI_10_FONT_ID, startY + LINE_SPACING * 3, hostnameUrl.c_str(), true, EpdFontFamily::BOLD);
// Show IP address as fallback
std::string ipUrl = "or http://" + connectedIP + "/";
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 4, ipUrl.c_str());
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 5, "Open this URL in your browser");
// Show QR code for URL
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 6, "or scan QR code with your phone:");
drawQRCode(renderer, (480 - 6 * 33) / 2, startY + LINE_SPACING * 7, hostnameUrl);
} else {
// STA mode display (original behavior)
const int startY = 65;
std::string ssidInfo = "Network: " + connectedSSID;
if (ssidInfo.length() > 28) {
ssidInfo.replace(25, ssidInfo.length() - 25, "...");
}
renderer.drawCenteredText(UI_10_FONT_ID, startY, ssidInfo.c_str());
std::string ipInfo = "IP Address: " + connectedIP;
renderer.drawCenteredText(UI_10_FONT_ID, startY + LINE_SPACING, ipInfo.c_str());
// Show web server URL prominently
std::string webInfo = "http://" + connectedIP + "/";
renderer.drawCenteredText(UI_10_FONT_ID, startY + LINE_SPACING * 2, webInfo.c_str(), true, EpdFontFamily::BOLD);
// Also show hostname URL
std::string hostnameUrl = std::string("or http://") + AP_HOSTNAME + ".local/";
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 3, hostnameUrl.c_str());
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 4, "Open this URL in your browser");
// Show QR code for URL
drawQRCode(renderer, (480 - 6 * 33) / 2, startY + LINE_SPACING * 6, webInfo);
renderer.drawCenteredText(SMALL_FONT_ID, startY + LINE_SPACING * 5, "or scan QR code with your phone:");
}
const auto labels = mappedInput.mapLabels("« Exit", "", "", "");
renderer.drawButtonHints(UI_10_FONT_ID, labels.btn1, labels.btn2, labels.btn3, labels.btn4);
}