Fix ESP32 badge critical RX mutex and build regressions

platform/espidf/projects/dashcdg_badge/main/badge_exec.c

@@ -277,6 +277,19 @@ int dashcdg_badge_exec_get_boot_complete_state(void)
     return 0;
 }
 
+static void badge_exec_append_text(char *out, size_t out_len, size_t *off, const char *text)
+{
+    if (out == NULL || out_len == 0U || off == NULL || text == NULL) {
+        return;
+    }
+    while (*text != '\0' && *off + 1U < out_len) {
+        out[*off] = *text;
+        (*off)++;
+        text++;
+    }
+    out[*off] = '\0';
+}
+
 /*
  * Build a short human-readable reason describing why the boot was DEGRADED. Each contributing bit
  * adds its short tag to a comma-separated list. NOMINAL boots produce "ok".
@@ -380,10 +393,14 @@ esp_err_t dashcdg_badge_exec_decide_boot_complete(void)
         if ((bits & hw_any) == 0U) { BADGE_EXEC_MISSING_APPEND(hw_any, "hw"); }
 #undef BADGE_EXEC_MISSING_APPEND
         char merged[sizeof(reason)];
-        snprintf(merged, sizeof(merged), "missing=%s%s%s",
-                 missing,
-                 reason[0] ? "," : "",
-                 reason[0] ? reason : "");
+        size_t merged_off = 0U;
+        merged[0] = '\0';
+        badge_exec_append_text(merged, sizeof(merged), &merged_off, "missing=");
+        badge_exec_append_text(merged, sizeof(merged), &merged_off, missing);
+        if (reason[0] != '\0') {
+            badge_exec_append_text(merged, sizeof(merged), &merged_off, ",");
+            badge_exec_append_text(merged, sizeof(merged), &merged_off, reason);
+        }
         return dashcdg_badge_exec_set_boot_complete(true, merged);
     }
     return dashcdg_badge_exec_set_boot_complete(degraded, reason);

platform/espidf/projects/dashcdg_badge/main/badge_rx.c

@@ -4199,7 +4199,7 @@ static int badge_rx_reset_for_new_session_locked(uint64_t local_now_ms)
     return 0;
 }
 
-static void handle_session_info(const struct dashcdg_packet_view *view)
+static int handle_session_info(const struct dashcdg_packet_view *view)
 {
     int same_session;
 
@@ -4231,11 +4231,16 @@ static void handle_session_info(const struct dashcdg_packet_view *view)
         } else {
             s_session_epoch_sender_floor_ms = view->header.sender_time_ms;
         }
-        return;
+        return 1;
     }
 
     if (badge_rx_reset_for_new_session_locked(dashcdg_clock_now_ms()) != 0) {
-        return;
+        /*
+         * badge_rx_reset_for_new_session_locked drops s_mtx before heavyweight reset work.
+         * A non-zero return means it failed to re-acquire s_mtx before the bounded timeout,
+         * so the pump must not perform its normal unconditional give for this datagram.
+         */
+        return 0;
     }
 
     s_active_session_start_ms = view->v4_session_info.session_start_ms;
@@ -4251,6 +4256,7 @@ static void handle_session_info(const struct dashcdg_packet_view *view)
     memcpy(s_stats.song_id, view->v4_session_info.song_id, DASHCDG_MAX_SONG_ID);
     s_stats.song_id[DASHCDG_MAX_SONG_ID] = '\0';
     s_stats.v4_session_count++;
+    return 1;
 }
 
 static void handle_clock_sync(const struct dashcdg_packet_view *view, uint64_t local_now_ms)
@@ -4759,14 +4765,14 @@ static void badge_rx_process_repair_datagram(const uint8_t *buf, size_t buflen)
     }
 }
 
-static void rx_one_datagram(uint8_t *buf, size_t buflen, uint64_t local_now_ms)
+static int rx_one_datagram(uint8_t *buf, size_t buflen, uint64_t local_now_ms)
 {
     struct dashcdg_packet_view view;
     uint64_t seq;
 
     if (!dashcdg_protocol_parse_packet(&view, buf, buflen)) {
         s_stats.parse_failures++;
-        return;
+        return 1;
     }
 
     seq = view.header.sequence;
@@ -4785,8 +4791,7 @@ static void rx_one_datagram(uint8_t *buf, size_t buflen, uint64_t local_now_ms)
 
     switch (view.header.type) {
     case DASHCDG_PACKET_V4_SESSION_INFO:
-        handle_session_info(&view);
-        break;
+        return handle_session_info(&view);
     case DASHCDG_PACKET_V4_CLOCK_SYNC:
         handle_clock_sync(&view, local_now_ms);
         /* `drain_cdg_to_idle` walks CDG jitter + audio; skip CDG drain when video decode is off. */
@@ -4833,6 +4838,7 @@ static void rx_one_datagram(uint8_t *buf, size_t buflen, uint64_t local_now_ms)
     default:
         break;
     }
+    return 1;
 }
 
 static void badge_rx_deferred_audio_drain_if_pending_locked(uint64_t local_now_ms)
@@ -4942,8 +4948,9 @@ static void badge_rx_pump_main_fd(int pump_fd, uint8_t *buf, size_t buf_cap)
 #if defined(CONFIG_DASHCDG_BADGE_PERF_PROBES) && CONFIG_DASHCDG_BADGE_PERF_PROBES
                     const int64_t t_hold0 = esp_timer_get_time();
 #endif
+                    int still_holds_mtx;
                     s_stats.datagrams++;
-                    rx_one_datagram(buf, (size_t)n, now_ms);
+                    still_holds_mtx = rx_one_datagram(buf, (size_t)n, now_ms);
 #if defined(CONFIG_DASHCDG_BADGE_PERF_PROBES) && CONFIG_DASHCDG_BADGE_PERF_PROBES
                     {
                         int64_t dt_hold = esp_timer_get_time() - t_hold0;
@@ -4953,8 +4960,10 @@ static void badge_rx_pump_main_fd(int pump_fd, uint8_t *buf, size_t buf_cap)
                         }
                     }
 #endif
-                    xSemaphoreGive(s_mtx);
-                    badge_rx_pump_flush_deferred_audio_drain(now_ms);
+                    if (still_holds_mtx) {
+                        xSemaphoreGive(s_mtx);
+                        badge_rx_pump_flush_deferred_audio_drain(now_ms);
+                    }
                     dashcdg_platform_hw_note_karaoke_mcast_rx(now_ms);
                     /*
                      * T7: mark progress (not just heartbeat) so the liveness sweep can tell

platform/espidf/projects/dashcdg_badge/main/sfx_touch.c

@@ -5,6 +5,7 @@
 
 #include "audio_mgr.h"
 #include "badge_exec.h"
+#include "platform_hw.h"
 
 #include "freertos/FreeRTOS.h"
 #include "freertos/queue.h"
@@ -38,6 +39,14 @@ static void sfx_task_fn(void *arg)
         /* Best-effort: do not crash if audio_mgr init fails. */
         (void)dashcdg_audio_mgr_init();
 
+        /*
+         * The chirp uses the shared DAC path at 24 kHz. Do not let a UI touch tear down an
+         * active karaoke RX stream (48 kHz line rate) just to reopen the DAC for SFX.
+         */
+        if (dashcdg_platform_hw_dac_route_owner() == DASHCDG_DAC_ROUTE_KARAOKE_RX) {
+            continue;
+        }
+
         /* 80 ms chirp @ 24 kHz. */
         enum { FS = 24000, MS = 80, N = (FS * MS) / 1000 };
         static int16_t pcm[N];

platform/espidf/projects/dashcdg_badge/main/wifi_touch_ui.c

@@ -304,10 +304,22 @@ static void wifi_touch_clamp_ps_none_if_rx_active(void)
 /** ESP-IDF `wifi_config_t` SSID/password are fixed arrays; avoid `strncpy(..., n-1)` — GCC stringop-truncation. */
 static void wifi_touch_copy_to_cfg_field(uint8_t *dst, size_t dst_sz, const char *src)
 {
+    size_t i = 0U;
+
     if (dst == NULL || dst_sz == 0U) {
         return;
     }
-    snprintf((char *)dst, dst_sz, "%s", (src != NULL) ? src : "");
+    if (src == NULL) {
+        src = "";
+    }
+    while (src[i] != '\0' && i + 1U < dst_sz) {
+        dst[i] = (uint8_t)src[i];
+        i++;
+    }
+    dst[i] = '\0';
+    if (i + 1U < dst_sz) {
+        memset(dst + i + 1U, 0, dst_sz - i - 1U);
+    }
 }
 static esp_netif_t *s_wifi_sta_netif;
 static const char *NVS_NS = "dashcfg";