feat: QEMU ESP32-S3 testing platform + swarm configurator (ADR-061/062)

.github/workflows/firmware-qemu.yml

@@ -0,0 +1,355 @@
+name: Firmware QEMU Tests (ADR-061)
+
+on:
+  push:
+    paths:
+      - 'firmware/**'
+      - 'scripts/qemu-esp32s3-test.sh'
+      - 'scripts/validate_qemu_output.py'
+      - 'scripts/generate_nvs_matrix.py'
+      - 'scripts/qemu_swarm.py'
+      - 'scripts/swarm_health.py'
+      - 'scripts/swarm_presets/**'
+      - '.github/workflows/firmware-qemu.yml'
+  pull_request:
+    paths:
+      - 'firmware/**'
+      - 'scripts/qemu-esp32s3-test.sh'
+      - 'scripts/validate_qemu_output.py'
+      - 'scripts/generate_nvs_matrix.py'
+      - 'scripts/qemu_swarm.py'
+      - 'scripts/swarm_health.py'
+      - 'scripts/swarm_presets/**'
+      - '.github/workflows/firmware-qemu.yml'
+
+env:
+  IDF_VERSION: "v5.4"
+  QEMU_REPO: "https://github.com/espressif/qemu.git"
+  QEMU_BRANCH: "esp-develop"
+
+jobs:
+  build-qemu:
+    name: Build Espressif QEMU
+    runs-on: ubuntu-latest
+    steps:
+      - name: Cache QEMU build
+        id: cache-qemu
+        uses: actions/cache@v4
+        with:
+          path: /opt/qemu-esp32
+          # Include date component so cache refreshes monthly when branch updates
+          key: qemu-esp32s3-${{ env.QEMU_BRANCH }}-v4
+          restore-keys: |
+            qemu-esp32s3-${{ env.QEMU_BRANCH }}-
+
+      - name: Install QEMU build dependencies
+        if: steps.cache-qemu.outputs.cache-hit != 'true'
+        run: |
+          sudo apt-get update
+          sudo apt-get install -y \
+            git build-essential ninja-build pkg-config \
+            libglib2.0-dev libpixman-1-dev libslirp-dev \
+            python3 python3-venv
+
+      - name: Clone and build Espressif QEMU
+        if: steps.cache-qemu.outputs.cache-hit != 'true'
+        run: |
+          git clone --depth 1 -b "$QEMU_BRANCH" "$QEMU_REPO" /tmp/qemu-esp
+          cd /tmp/qemu-esp
+          mkdir build && cd build
+          ../configure \
+            --target-list=xtensa-softmmu \
+            --prefix=/opt/qemu-esp32 \
+            --enable-slirp \
+            --disable-werror
+          ninja -j$(nproc)
+          ninja install
+
+      - name: Verify QEMU binary
+        run: |
+          file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
+          /opt/qemu-esp32/bin/qemu-system-xtensa --version
+          echo "QEMU binary size: $(file_size /opt/qemu-esp32/bin/qemu-system-xtensa) bytes"
+
+      - name: Upload QEMU artifact
+        uses: actions/upload-artifact@v4
+        with:
+          name: qemu-esp32
+          path: /opt/qemu-esp32/
+          retention-days: 7
+
+  qemu-test:
+    name: QEMU Test (${{ matrix.nvs_config }})
+    needs: build-qemu
+    runs-on: ubuntu-latest
+    container:
+      image: espressif/idf:v5.4
+
+    strategy:
+      fail-fast: false
+      matrix:
+        nvs_config:
+          - default
+          - full-adr060
+          - edge-tier0
+          - edge-tier1
+          - tdm-3node
+          - boundary-max
+          - boundary-min
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Download QEMU artifact
+        uses: actions/download-artifact@v4
+        with:
+          name: qemu-esp32
+          path: /opt/qemu-esp32
+
+      - name: Make QEMU executable
+        run: chmod +x /opt/qemu-esp32/bin/qemu-system-xtensa
+
+      - name: Verify QEMU works
+        run: /opt/qemu-esp32/bin/qemu-system-xtensa --version
+
+      - name: Install Python dependencies
+        run: pip install esptool esp-idf-nvs-partition-gen
+
+      - name: Set target ESP32-S3
+        working-directory: firmware/esp32-csi-node
+        run: |
+          . $IDF_PATH/export.sh
+          idf.py set-target esp32s3
+
+      - name: Build firmware (mock CSI mode)
+        working-directory: firmware/esp32-csi-node
+        run: |
+          . $IDF_PATH/export.sh
+          idf.py \
+            -D SDKCONFIG_DEFAULTS="sdkconfig.defaults;sdkconfig.qemu" \
+            build
+
+      - name: Generate NVS matrix
+        run: |
+          python3 scripts/generate_nvs_matrix.py \
+            --output-dir firmware/esp32-csi-node/build/nvs_matrix \
+            --only ${{ matrix.nvs_config }}
+
+      - name: Create merged flash image
+        working-directory: firmware/esp32-csi-node
+        run: |
+          . $IDF_PATH/export.sh
+
+          # Determine merge_bin arguments
+          OTA_ARGS=""
+          if [ -f build/ota_data_initial.bin ]; then
+            OTA_ARGS="0xf000 build/ota_data_initial.bin"
+          fi
+
+          python3 -m esptool --chip esp32s3 merge_bin \
+            -o build/qemu_flash.bin \
+            --flash_mode dio --flash_freq 80m --flash_size 8MB \
+            0x0     build/bootloader/bootloader.bin \
+            0x8000  build/partition_table/partition-table.bin \
+            $OTA_ARGS \
+            0x20000 build/esp32-csi-node.bin
+
+          file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
+          echo "Flash image size: $(file_size build/qemu_flash.bin) bytes"
+
+      - name: Inject NVS partition
+        if: matrix.nvs_config != 'default'
+        working-directory: firmware/esp32-csi-node
+        run: |
+          NVS_BIN="build/nvs_matrix/nvs_${{ matrix.nvs_config }}.bin"
+          if [ -f "$NVS_BIN" ]; then
+            file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
+            echo "Injecting NVS: $NVS_BIN ($(file_size "$NVS_BIN") bytes)"
+            dd if="$NVS_BIN" of=build/qemu_flash.bin \
+              bs=1 seek=$((0x9000)) conv=notrunc 2>/dev/null
+          else
+            echo "WARNING: NVS binary not found: $NVS_BIN"
+          fi
+
+      - name: Run QEMU smoke test
+        env:
+          QEMU_PATH: /opt/qemu-esp32/bin/qemu-system-xtensa
+          QEMU_TIMEOUT: "90"
+        run: |
+          echo "Starting QEMU (timeout: ${QEMU_TIMEOUT}s)..."
+
+          timeout "$QEMU_TIMEOUT" "$QEMU_PATH" \
+            -machine esp32s3 \
+            -nographic \
+            -drive file=firmware/esp32-csi-node/build/qemu_flash.bin,if=mtd,format=raw \
+            -serial mon:stdio \
+            -nic user,model=open_eth,net=10.0.2.0/24 \
+            -no-reboot \
+            2>&1 | tee firmware/esp32-csi-node/build/qemu_output.log || true
+
+          echo "QEMU finished. Log size: $(wc -l < firmware/esp32-csi-node/build/qemu_output.log) lines"
+
+      - name: Validate QEMU output
+        run: |
+          python3 scripts/validate_qemu_output.py \
+            firmware/esp32-csi-node/build/qemu_output.log
+
+      - name: Upload test logs
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: qemu-logs-${{ matrix.nvs_config }}
+          path: |
+            firmware/esp32-csi-node/build/qemu_output.log
+            firmware/esp32-csi-node/build/nvs_matrix/
+          retention-days: 14
+
+  fuzz-test:
+    name: Fuzz Testing (ADR-061 Layer 6)
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Install clang
+        run: |
+          sudo apt-get update
+          sudo apt-get install -y clang
+
+      - name: Build fuzz targets
+        working-directory: firmware/esp32-csi-node/test
+        run: make all CC=clang
+
+      - name: Run serialize fuzzer (60s)
+        working-directory: firmware/esp32-csi-node/test
+        run: make run_serialize FUZZ_DURATION=60 || echo "FUZZER_CRASH=serialize" >> "$GITHUB_ENV"
+
+      - name: Run edge enqueue fuzzer (60s)
+        working-directory: firmware/esp32-csi-node/test
+        run: make run_edge FUZZ_DURATION=60 || echo "FUZZER_CRASH=edge" >> "$GITHUB_ENV"
+
+      - name: Run NVS config fuzzer (60s)
+        working-directory: firmware/esp32-csi-node/test
+        run: make run_nvs FUZZ_DURATION=60 || echo "FUZZER_CRASH=nvs" >> "$GITHUB_ENV"
+
+      - name: Check for crashes
+        working-directory: firmware/esp32-csi-node/test
+        run: |
+          CRASHES=$(find . -type f \( -name "crash-*" -o -name "oom-*" -o -name "timeout-*" \) 2>/dev/null | wc -l)
+          echo "Crash artifacts found: $CRASHES"
+          if [ "$CRASHES" -gt 0 ] || [ -n "${FUZZER_CRASH:-}" ]; then
+            echo "::error::Fuzzer found $CRASHES crash/oom/timeout artifacts. FUZZER_CRASH=${FUZZER_CRASH:-none}"
+            ls -la crash-* oom-* timeout-* 2>/dev/null
+            exit 1
+          fi
+
+      - name: Upload fuzz artifacts
+        if: failure()
+        uses: actions/upload-artifact@v4
+        with:
+          name: fuzz-crashes
+          path: |
+            firmware/esp32-csi-node/test/crash-*
+            firmware/esp32-csi-node/test/oom-*
+            firmware/esp32-csi-node/test/timeout-*
+          retention-days: 30
+
+  nvs-matrix-validate:
+    name: NVS Matrix Generation
+    runs-on: ubuntu-latest
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Install NVS generator
+        run: pip install esp-idf-nvs-partition-gen
+
+      - name: Generate all 14 NVS configs
+        run: |
+          python3 scripts/generate_nvs_matrix.py \
+            --output-dir build/nvs_matrix
+
+      - name: Verify all binaries generated
+        run: |
+          EXPECTED=14
+          ACTUAL=$(find build/nvs_matrix -type f -name "nvs_*.bin" 2>/dev/null | wc -l)
+          echo "Generated $ACTUAL / $EXPECTED NVS binaries"
+          ls -la build/nvs_matrix/
+
+          if [ "$ACTUAL" -lt "$EXPECTED" ]; then
+            echo "::error::Only $ACTUAL of $EXPECTED NVS binaries generated"
+            exit 1
+          fi
+
+      - name: Verify binary sizes
+        run: |
+          file_size() { stat -c%s "$1" 2>/dev/null || stat -f%z "$1" 2>/dev/null || wc -c < "$1"; }
+          for f in build/nvs_matrix/nvs_*.bin; do
+            SIZE=$(file_size "$f")
+            if [ "$SIZE" -ne 24576 ]; then
+              echo "::error::$f has unexpected size $SIZE (expected 24576)"
+              exit 1
+            fi
+            echo "  OK: $(basename $f) ($SIZE bytes)"
+          done
+
+  # ---------------------------------------------------------------------------
+  # ADR-062: QEMU Swarm Configurator Test
+  #
+  # Runs a lightweight 3-node swarm (ci_matrix preset) under QEMU to validate
+  # multi-node orchestration, TDM slot coordination, and swarm-level health
+  # assertions. Uses the pre-built QEMU binary from the build-qemu job and the
+  # firmware built by qemu-test.
+  #
+  # The CI runner is non-root, so TAP bridge networking is unavailable.
+  # The orchestrator (qemu_swarm.py) detects this and falls back to SLIRP
+  # user-mode networking, which is sufficient for the ci_matrix preset.
+  # ---------------------------------------------------------------------------
+  swarm-test:
+    name: Swarm Test (ADR-062)
+    needs: [build-qemu]
+    runs-on: ubuntu-latest
+    container:
+      image: espressif/idf:v5.4
+
+    steps:
+      - uses: actions/checkout@v4
+
+      - name: Download QEMU artifact
+        uses: actions/download-artifact@v4
+        with:
+          name: qemu-esp32
+          path: ${{ github.workspace }}/qemu-build
+
+      - name: Make QEMU executable
+        run: chmod +x ${{ github.workspace }}/qemu-build/bin/qemu-system-xtensa
+
+      - name: Install Python dependencies
+        run: pip install pyyaml esptool esp-idf-nvs-partition-gen
+
+      - name: Build firmware for swarm
+        working-directory: firmware/esp32-csi-node
+        run: |
+          . $IDF_PATH/export.sh
+          idf.py set-target esp32s3
+          idf.py -D SDKCONFIG_DEFAULTS="sdkconfig.defaults;sdkconfig.qemu" build
+          python3 -m esptool --chip esp32s3 merge_bin \
+            -o build/qemu_flash.bin \
+            --flash_mode dio --flash_freq 80m --flash_size 8MB \
+            0x0     build/bootloader/bootloader.bin \
+            0x8000  build/partition_table/partition-table.bin \
+            0x20000 build/esp32-csi-node.bin
+
+      - name: Run swarm smoke test
+        run: |
+          python3 scripts/qemu_swarm.py --preset ci_matrix \
+            --qemu-path ${{ github.workspace }}/qemu-build/bin/qemu-system-xtensa \
+            --output-dir build/swarm-results
+        timeout-minutes: 10
+
+      - name: Upload swarm results
+        if: always()
+        uses: actions/upload-artifact@v4
+        with:
+          name: swarm-results
+          path: |
+            build/swarm-results/
+          retention-days: 14