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Fix robotic audio + crash: proper FIFO delay line

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The previous delay buffer re-derived the read position from the write head on
every A2DP pull (read = write - delay), so it sampled the buffer at the
Bluetooth pull-rate while positioning by the I2S write-rate — skipping/
repeating samples (robotic) and, with no cushion at delay=0, constantly
under/overrunning until it destabilized and crashed.

Replace with a real FIFO: a sequential read pointer that advances by the
frames consumed, held BASE_DELAY_MS (40 ms jitter cushion) + the touch trim
behind the I2S write head, with underrun (pad silence) and overrun (resync)
handling. Also carry partial frames across I2S reads so L/R never slips.

Verified on hardware: clean audio to both speakers, stable for hours,
touch-pad sync aligns JBL and Cardo.

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
This commit is contained in:
blue — ESP32/PlatformIO firmware 2026-06-10 16:07:49 -04:00
parent 66f56f1e09
commit 0b1c34074f
1 changed files with 67 additions and 44 deletions
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111
src/board_source.cpp
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@ -1,24 +1,23 @@
/** /**
* BikeAudio — Boards B & C : I2S SLAVE -> [touch-adjustable delay] -> A2DP SOURCE * BikeAudio — Boards B & C : I2S SLAVE -> [FIFO delay] -> A2DP SOURCE
* *
* Reads PCM from the shared I2S bus (clocked by Board A), passes it through an * Reads PCM from the shared I2S bus (clocked by Board A) into a FIFO, and an
* adjustable delay line, and streams it to ONE Bluetooth speaker. The delay lets * A2DP source drains the FIFO to one Bluetooth speaker. The FIFO sits a fixed
* you sync this speaker against the other one, tuned live BY EAR with two * jitter cushion (BASE_DELAY_MS) plus an adjustable trim behind the I2S write
* capacitive-touch pads (+ / -). The value is saved to flash (survives reboots). * head; the trim (0..MAX_DELAY_MS) is set live BY EAR with two capacitive-touch
* pads to align this speaker against the other one, and is saved to flash.
* *
* No Wi-Fi: Wi-Fi + Bluetooth-A2DP + the audio buffer don't fit in RAM on this * No Wi-Fi: Wi-Fi + Bluetooth + buffer don't fit in RAM on the classic ESP32.
* chip (the BT stack gets starved and won't connect), so the control is local
* touch rather than a phone UI. With Wi-Fi gone there's ~120 KB of heap free.
* *
* Per-env build flag: TARGET_SPEAKER ("JBL Charge 5" / "Tangerine EDGE"). * Per-env build flag: TARGET_SPEAKER ("JBL Charge 5" / "Tangerine EDGE").
* *
* Wiring: * Wiring:
* I2S in (from Board A): BCK=GPIO19 WS=GPIO18 DATA=GPIO22 + GND * I2S in (from Board A): BCK=GPIO19 WS=GPIO18 DATA=GPIO22 + GND
* Touch "+" : GPIO4 (T0) Touch "-" : GPIO27 (T7) * Touch "+" : GPIO4 (T0) Touch "-" : GPIO27 (T7) (attach a wire/pad)
* (attach a short wire or a bit of foil to each; tap = one step, hold = ramp)
*/ */
#include <Arduino.h> #include <Arduino.h>
#include <string.h>
#include "AudioTools.h" #include "AudioTools.h"
#include "BluetoothA2DPSource.h" #include "BluetoothA2DPSource.h"
@ -34,57 +33,82 @@
#define TOUCH_PLUS T0 // GPIO4 #define TOUCH_PLUS T0 // GPIO4
#define TOUCH_MINUS T7 // GPIO27 #define TOUCH_MINUS T7 // GPIO27
#define TOUCH_THRESH 40 // touchRead below this = touched (calibrate via serial) #define TOUCH_THRESH 40 // touchRead below this = touched
#define SR_HZ 44100 #define SR_HZ 44100
#define MAX_DELAY_MS 200 #define BASE_DELAY_MS 40 // fixed jitter cushion (applied to both speakers)
#define MAX_DELAY_MS 200 // adjustable trim on top of the cushion
#define DELAY_STEP_MS 5 #define DELAY_STEP_MS 5
#define TOUCH_REPEAT_MS 150 // tap = one step; hold = a step every 150 ms #define TOUCH_REPEAT_MS 150
#define RING_FRAMES (((uint32_t)SR_HZ * (MAX_DELAY_MS + 20)) / 1000) #define RING_MS (BASE_DELAY_MS + MAX_DELAY_MS + 40) // + headroom
#define RING_FRAMES ((uint32_t)SR_HZ * RING_MS / 1000)
#define BASE_FRAMES ((uint32_t)SR_HZ * BASE_DELAY_MS / 1000)
I2SStream i2s; I2SStream i2s;
BluetoothA2DPSource source; BluetoothA2DPSource source;
Preferences prefs; Preferences prefs;
// FIFO of interleaved L,R int16. Producer = i2s_task, consumer = A2DP callback.
static int16_t ring[RING_FRAMES * 2]; static int16_t ring[RING_FRAMES * 2];
static volatile uint32_t write_frames = 0; static volatile uint32_t write_frames = 0; // producer position (monotonic)
static volatile uint32_t delay_frames = 0; static volatile uint32_t read_frames = 0; // consumer position (monotonic)
static volatile uint32_t trim_frames = 0; // adjustable delay (frames)
static volatile bool primed = false; // FIFO has reached target fill
static volatile uint16_t delay_ms_current = 0; static volatile uint16_t delay_ms_current = 0;
static bool save_pending = false; static bool save_pending = false;
static unsigned long last_change_ms = 0; static unsigned long last_change_ms = 0;
// Continuously pull I2S into the ring (paced by Board A's clock). // Continuously pull I2S into the FIFO (paced by Board A's master clock).
// Carry any partial frame across reads so L/R never slips out of alignment.
static void i2s_task(void *arg) { static void i2s_task(void *arg) {
static int16_t tmp[256 * 2]; static uint8_t buf[1024];
static int rem = 0;
for (;;) { for (;;) {
size_t bytes = i2s.readBytes((uint8_t *)tmp, sizeof(tmp)); size_t got = i2s.readBytes(buf + rem, sizeof(buf) - rem);
int frames = bytes / 4; int total = rem + (int)got;
int frames = total / 4;
int16_t *s = (int16_t *)buf;
for (int i = 0; i < frames; i++) { for (int i = 0; i < frames; i++) {
uint32_t w = write_frames % RING_FRAMES; uint32_t w = write_frames % RING_FRAMES;
ring[w * 2] = tmp[i * 2]; ring[w * 2] = s[i * 2];
ring[w * 2 + 1] = tmp[i * 2 + 1]; ring[w * 2 + 1] = s[i * 2 + 1];
write_frames++; write_frames++;
} }
if (frames == 0) vTaskDelay(1); // no clock yet (Board A down) — don't spin rem = total - frames * 4;
if (rem > 0) memmove(buf, buf + frames * 4, rem);
if (got == 0) vTaskDelay(1); // no clock yet (Board A down) — don't spin
} }
} }
// A2DP pulls frames; serve them delayed by delay_frames behind the write head. // A2DP drains the FIFO sequentially, kept (BASE_FRAMES + trim) behind the write head.
int32_t read_delayed(Frame *data, int32_t frame_count) { int32_t read_delayed(Frame *data, int32_t fc) {
uint32_t d = delay_frames; uint32_t w = write_frames;
if (d < (uint32_t)frame_count) d = frame_count; // never read past the write head uint32_t target = BASE_FRAMES + trim_frames; // desired gap behind write head
uint32_t w = write_frames;
if (w < d) { if (!primed) {
for (int32_t i = 0; i < frame_count; i++) { data[i].channel1 = 0; data[i].channel2 = 0; } if (w < target + (uint32_t)fc) { // not buffered enough yet -> silence
return frame_count; for (int32_t i = 0; i < fc; i++) { data[i].channel1 = 0; data[i].channel2 = 0; }
return fc;
}
read_frames = w - target;
primed = true;
} }
uint32_t start = w - d;
for (int32_t i = 0; i < frame_count; i++) { uint32_t avail = w - read_frames; // frames available to read
uint32_t idx = (start + i) % RING_FRAMES; if (avail > RING_FRAMES) { // producer lapped us (big drift) -> resync
read_frames = (w > target) ? (w - target) : 0;
avail = w - read_frames;
}
int32_t n = ((uint32_t)fc <= avail) ? fc : (int32_t)avail;
for (int32_t i = 0; i < n; i++) {
uint32_t idx = (read_frames + i) % RING_FRAMES;
data[i].channel1 = ring[idx * 2]; data[i].channel1 = ring[idx * 2];
data[i].channel2 = ring[idx * 2 + 1]; data[i].channel2 = ring[idx * 2 + 1];
} }
return frame_count; read_frames += n;
for (int32_t i = n; i < fc; i++) { data[i].channel1 = 0; data[i].channel2 = 0; } // pad underrun
return fc;
} }
static void set_delay(int ms) { static void set_delay(int ms) {
@ -92,7 +116,8 @@ static void set_delay(int ms) {
if (ms > MAX_DELAY_MS) ms = MAX_DELAY_MS; if (ms > MAX_DELAY_MS) ms = MAX_DELAY_MS;
if ((uint16_t)ms == delay_ms_current) return; if ((uint16_t)ms == delay_ms_current) return;
delay_ms_current = (uint16_t)ms; delay_ms_current = (uint16_t)ms;
delay_frames = ((uint32_t)ms * SR_HZ) / 1000; trim_frames = ((uint32_t)ms * SR_HZ) / 1000;
primed = false; // re-establish the FIFO gap at the new delay
save_pending = true; save_pending = true;
last_change_ms = millis(); last_change_ms = millis();
Serial.printf("[SRC %s] delay = %d ms\n", TARGET_SPEAKER, ms); Serial.printf("[SRC %s] delay = %d ms\n", TARGET_SPEAKER, ms);
@ -108,13 +133,13 @@ void on_conn_state(esp_a2d_connection_state_t state, void *obj) {
void setup() { void setup() {
Serial.begin(115200); Serial.begin(115200);
delay(500); delay(500);
Serial.printf("=== BikeAudio Source -> '%s' (touch-adjustable delay) ===\n", TARGET_SPEAKER); Serial.printf("=== BikeAudio Source -> '%s' (FIFO delay, %ums cushion) ===\n",
TARGET_SPEAKER, BASE_DELAY_MS);
prefs.begin("bikeaudio", false); prefs.begin("bikeaudio", false);
set_delay(prefs.getUShort("delay_ms", 0)); set_delay(prefs.getUShort("delay_ms", 0));
save_pending = false; // loading isn't a change to persist save_pending = false;
// I2S slave RX — follows Board A's clock.
auto cfg = i2s.defaultConfig(RX_MODE); auto cfg = i2s.defaultConfig(RX_MODE);
cfg.pin_bck = I2S_BCK_PIN; cfg.pin_ws = I2S_WS_PIN; cfg.pin_data = I2S_DATA_PIN; cfg.pin_bck = I2S_BCK_PIN; cfg.pin_ws = I2S_WS_PIN; cfg.pin_data = I2S_DATA_PIN;
cfg.sample_rate = SR_HZ; cfg.channels = 2; cfg.bits_per_sample = 16; cfg.sample_rate = SR_HZ; cfg.channels = 2; cfg.bits_per_sample = 16;
@ -128,14 +153,13 @@ void setup() {
source.set_auto_reconnect(true, 5); source.set_auto_reconnect(true, 5);
source.set_volume(100); source.set_volume(100);
source.start(TARGET_SPEAKER); source.start(TARGET_SPEAKER);
Serial.printf("[SRC] Connecting to '%s' — delay %u ms; touch + on GPIO4, - on GPIO27\n", Serial.printf("[SRC] Connecting to '%s' — trim %u ms; touch + GPIO4, - GPIO27\n",
TARGET_SPEAKER, delay_ms_current); TARGET_SPEAKER, delay_ms_current);
} }
void loop() { void loop() {
unsigned long now = millis(); unsigned long now = millis();
// Touch +/- (tap = one step, hold = ramp every TOUCH_REPEAT_MS).
static unsigned long last_touch = 0; static unsigned long last_touch = 0;
if (now - last_touch >= TOUCH_REPEAT_MS) { if (now - last_touch >= TOUCH_REPEAT_MS) {
bool plus = touchRead(TOUCH_PLUS) < TOUCH_THRESH; bool plus = touchRead(TOUCH_PLUS) < TOUCH_THRESH;
@ -144,7 +168,6 @@ void loop() {
else if (minus && !plus) { set_delay(delay_ms_current - DELAY_STEP_MS); last_touch = now; } else if (minus && !plus) { set_delay(delay_ms_current - DELAY_STEP_MS); last_touch = now; }
} }
// Persist to flash 1.5 s after the last change (avoids wear while ramping).
if (save_pending && now - last_change_ms > 1500) { if (save_pending && now - last_change_ms > 1500) {
prefs.putUShort("delay_ms", delay_ms_current); prefs.putUShort("delay_ms", delay_ms_current);
save_pending = false; save_pending = false;
@ -153,9 +176,9 @@ void loop() {
static unsigned long last_st = 0; static unsigned long last_st = 0;
if (now - last_st > 5000) { if (now - last_st > 5000) {
Serial.printf("[SRC %s] connected=%s delay=%ums heap=%u touch+=%u touch-=%u\n", Serial.printf("[SRC %s] connected=%s trim=%ums fill=%u heap=%u\n",
TARGET_SPEAKER, source.is_connected() ? "YES" : "no", delay_ms_current, TARGET_SPEAKER, source.is_connected() ? "YES" : "no", delay_ms_current,
ESP.getFreeHeap(), touchRead(TOUCH_PLUS), touchRead(TOUCH_MINUS)); (unsigned)(write_frames - read_frames), ESP.getFreeHeap());
last_st = now; last_st = now;
} }
delay(20); delay(20);