fix(usb): tether follows the USB bus state; WiFi failover off the PSRAM stack; distinct netif MAC

components/ml_dev_tether/src/ml_dev_tether.c

@@ -106,6 +106,63 @@ static esp_err_t on_usb_rx(void * buffer, uint16_t len, void * ctx)
   return r;
 }
 
+/* === USB bus state -> netif link state ============================ */
+
+/* The tether netif was brought up with a synthetic "link connected" and
+ * nothing ever took it down again: a host that de-enumerated us, suspended
+ * the bus, or simply went away left the netif up with its lease, so the net
+ * supervisor kept ranking a dead tether as the best uplink and never failed
+ * over (bench, 2026-09-18: host port de-authorised, device kept 10.42.0.x,
+ * no WiFi for minutes). Mirror the bus state onto the netif: detached or
+ * suspended -> link down (lease dropped, netif_usable() false, supervisor
+ * fails over); attached or resumed -> link up (DHCP restarts).
+ * Runs on the TinyUSB task; the same lock on_usb_rx() uses keeps it from
+ * racing ml_dev_tether_stop()'s esp_netif_destroy(). */
+static void on_usb_event(tinyusb_event_t * event, void * arg)
+{
+  (void)arg;
+  if (event == NULL) {
+    return;
+  }
+  bool link_up;
+  const char * what;
+  switch (event->id) {
+    case TINYUSB_EVENT_ATTACHED:
+      link_up = true;
+      what = "attached";
+      break;
+    case TINYUSB_EVENT_DETACHED:
+      link_up = false;
+      what = "detached";
+      break;
+#ifdef CONFIG_TINYUSB_SUSPEND_CALLBACK
+    case TINYUSB_EVENT_SUSPENDED:
+      link_up = false;
+      what = "suspended";
+      break;
+#endif
+#ifdef CONFIG_TINYUSB_RESUME_CALLBACK
+    case TINYUSB_EVENT_RESUMED:
+      link_up = true;
+      what = "resumed";
+      break;
+#endif
+    default:
+      return;
+  }
+  if (s_rx_lock) xSemaphoreTake(s_rx_lock, portMAX_DELAY);
+  esp_netif_t * n = s_netif;
+  if (n) {
+    ESP_LOGW(TAG, "USB %s -> tether link %s", what, link_up ? "up" : "down");
+    if (link_up) {
+      esp_netif_action_connected(n, 0, 0, 0);
+    } else {
+      esp_netif_action_disconnected(n, 0, 0, 0);
+    }
+  }
+  if (s_rx_lock) xSemaphoreGive(s_rx_lock);
+}
+
 /* === DHCP lease signal ============================================ */
 
 static void on_got_ip(void * arg, esp_event_base_t base, int32_t id, void * data)
@@ -163,7 +220,7 @@ esp_err_t ml_dev_tether_try_start(uint32_t timeout_ms)
 
   /* --- TinyUSB up --- */
   if (!s_tusb_installed) {
-    const tinyusb_config_t tusb_cfg = TINYUSB_DEFAULT_CONFIG();
+    const tinyusb_config_t tusb_cfg = TINYUSB_CONFIG_EVENT(on_usb_event);
     err = tinyusb_driver_install(&tusb_cfg);
     if (err != ESP_OK) {
       ESP_LOGE(TAG, "tinyusb_driver_install: %s", esp_err_to_name(err));
@@ -291,11 +348,17 @@ esp_err_t ml_dev_tether_try_start(uint32_t timeout_ms)
   }
   ml_usb_tx_set_enabled(1);
 
-  /* Use the SAME MAC for the lwIP netif as the NCM endpoint. The IDF
-     * sta2eth example uses different MACs because it bridges to a separate
-     * DHCP server; in our DHCP-CLIENT topology there's a single logical
-     * endpoint and ARP/DHCP must resolve to the same MAC the host sees. */
-  esp_netif_set_mac(s_netif, net_cfg.mac_addr);
+  /* The MAC handed to tinyusb_net_init() is the one the HOST adopts for its
+     * side of the link (CDC-NCM iMACAddress); the lwIP netif is the other end
+     * and needs its own address, like any two NICs on a cable. Sharing one
+     * address (as before) had the host learn the device's IP at the host's
+     * own MAC — it happened to work on Linux, but is a spec violation and
+     * indistinguishable frames in any capture. Flip one more bit: still
+     * locally administered, still derived from the unit's WiFi MAC. */
+  uint8_t dev_mac[6];
+  memcpy(dev_mac, net_cfg.mac_addr, sizeof(dev_mac));
+  dev_mac[5] ^= 0x02;
+  esp_netif_set_mac(s_netif, dev_mac);
 
   /* Bring up the netif and also signal "link connected" — without this,
      * the Ethernet-class netif stays in admin-up/link-down state and the

firmware/components/dcs_support/src/dcs_net_supervisor.c

@@ -35,6 +35,7 @@
 #include "esp_timer.h"
 #include "esp_wifi.h"
 #include "freertos/FreeRTOS.h"
+#include "freertos/semphr.h"
 #include "freertos/task.h"
 #include "ml_app.h"
 
@@ -45,6 +46,53 @@ static const char * TAG = "dcs_netsup";
  * poll period. Only DOWN transitions kick — UP/promote stays on the periodic
  * loop for natural anti-flap debounce (asymmetric by design). */
 static TaskHandle_t s_sup_task = NULL;
+
+/* dcs_wifi_set_enabled() reaches flash: the wifi_list NVS blob, and
+ * esp_wifi_init/start's PHY-calibration NVS access. Flash access asserts when
+ * the caller's stack is in PSRAM (cache_utils.c:127,
+ * esp_task_stack_is_sane_cache_disabled) — and the supervisor's is. So the
+ * toggle runs on a short-lived INTERNAL-stack worker and the supervisor only
+ * waits on a dedicated semaphore (its task notification is the link-down
+ * wake-up and must not be consumed here). Bench 2026-09-19 (cad4): tether
+ * link-down -> "bringing up WiFi" -> assert abort in net_sup, boot loop. */
+typedef struct
+{
+  bool on;
+  esp_err_t result;
+} wifi_toggle_req_t;
+
+static SemaphoreHandle_t s_wifi_toggle_done = NULL;
+static wifi_toggle_req_t s_wifi_toggle_req; /* one caller (this task), one toggle at a time */
+
+static void wifi_toggle_task(void * arg)
+{
+  wifi_toggle_req_t * req = (wifi_toggle_req_t *)arg;
+  req->result = dcs_wifi_set_enabled(req->on);
+  (void)xSemaphoreGive(s_wifi_toggle_done);
+  vTaskDelete(NULL);
+}
+
+static esp_err_t wifi_set_enabled_on_internal_stack(bool on)
+{
+  if (s_wifi_toggle_done == NULL) {
+    s_wifi_toggle_done = xSemaphoreCreateBinary();
+    if (s_wifi_toggle_done == NULL) {
+      return ESP_ERR_NO_MEM;
+    }
+  }
+  s_wifi_toggle_req.on = on;
+  s_wifi_toggle_req.result = ESP_FAIL;
+  /* Internal stack by construction (plain xTaskCreate): 4 KB, transient. */
+  if (
+    xTaskCreatePinnedToCore(wifi_toggle_task, "wifi_tog", 4096, &s_wifi_toggle_req, 4, NULL, tskNO_AFFINITY) != pdPASS)
+  {
+    ESP_LOGW(TAG, "WiFi toggle worker: no internal RAM for its stack — retry next tick");
+    return ESP_ERR_NO_MEM;
+  }
+  (void)xSemaphoreTake(s_wifi_toggle_done, portMAX_DELAY); /* worker always gives before exiting */
+  return s_wifi_toggle_req.result;
+}
+
 static atomic_uint s_link_down_kicks = 0;
 
 #define SUPERVISOR_PERIOD_MS 1000
@@ -209,12 +257,12 @@ static void supervisor_task(void * arg)
       if (dcs_boot_alt_network_won()) {
         if ((!high_ok) && (high_bad_s >= WIFI_FAILOVER_AFTER_S) && (!dcs_wifi_is_enabled())) {
           ESP_LOGW(TAG, "no Eth/USB for %us — bringing up WiFi", (unsigned)high_bad_s);
-          if (dcs_wifi_set_enabled(true) == ESP_OK) {
+          if (wifi_set_enabled_on_internal_stack(true) == ESP_OK) {
             wifi_auto = true;
           }
         } else if (high_ok && (high_ok_s >= FAILOVER_DROP_HOLD_S) && wifi_auto && dcs_wifi_is_enabled()) {
           ESP_LOGW(TAG, "Eth/USB stable %us — dropping WiFi", (unsigned)high_ok_s);
-          if (dcs_wifi_set_enabled(false) == ESP_OK) {
+          if (wifi_set_enabled_on_internal_stack(false) == ESP_OK) {
             wifi_auto = false;
           }
         } else {
@@ -239,10 +287,9 @@ static void supervisor_task(void * arg)
 void dcs_net_supervisor_start(void)
 {
   atomic_store(&g_dcs_active_iface, (int)DCS_IFACE_NONE);
-  /* 4608 B: the task now calls dcs_wifi_set_enabled() (esp_wifi_init/deinit,
-     * esp_netif create/destroy) on auto-failover, which needs more stack than
-     * the bare route-arbitration loop. */
-  /* PSRAM stack: route supervisor is non-safety, does no flash/NVS. */
+  /* PSRAM stack: route supervisor is non-safety and does no flash/NVS itself —
+     * the WiFi failover toggle, which does, runs on an internal-stack worker
+     * (wifi_set_enabled_on_internal_stack). */
   s_sup_task = dcs_task_spawn_psram(supervisor_task, "net_sup", 4608, NULL, 4, tskNO_AFFINITY);
 
   /* Event-driven demote: wake the supervisor the instant a link drops so it

firmware/sdkconfig.defaults

@@ -196,6 +196,10 @@ CONFIG_TINYUSB_CDC_COUNT=1
 CONFIG_ESP_CONSOLE_SECONDARY_USB_SERIAL_JTAG=n
 CONFIG_TINYUSB_CDC_RX_BUFSIZE=512
 CONFIG_TINYUSB_CDC_TX_BUFSIZE=512
+# Bus suspend/resume events: the tether mirrors them onto its netif link
+# state so the net supervisor fails over when the host goes away.
+CONFIG_TINYUSB_SUSPEND_CALLBACK=y
+CONFIG_TINYUSB_RESUME_CALLBACK=y
 # USB descriptors
 CONFIG_TINYUSB_DESC_MANUFACTURER_STRING="Polymath"
 CONFIG_TINYUSB_DESC_PRODUCT_STRING="MicroLink dual_core_safety"

machn/sdkconfig.defaults

@@ -163,6 +163,10 @@ CONFIG_TINYUSB_CDC_COUNT=1
 CONFIG_ESP_CONSOLE_SECONDARY_USB_SERIAL_JTAG=n
 CONFIG_TINYUSB_CDC_RX_BUFSIZE=512
 CONFIG_TINYUSB_CDC_TX_BUFSIZE=512
+# Bus suspend/resume events: the tether mirrors them onto its netif link
+# state so the net supervisor fails over when the host goes away.
+CONFIG_TINYUSB_SUSPEND_CALLBACK=y
+CONFIG_TINYUSB_RESUME_CALLBACK=y
 # USB descriptors
 CONFIG_TINYUSB_DESC_MANUFACTURER_STRING="Polymath"
 CONFIG_TINYUSB_DESC_PRODUCT_STRING="MicroLink dual_core_safety"