size.yml

name: Firmware Size Tracking

on:
  push:
    branches: [main]
  pull_request:
    branches: [main]

jobs:
  size:
    runs-on: ubuntu-latest
    strategy:
      fail-fast: false
      matrix:
        include:
          - project: BMS
            flash_limit: 524288
          - project: PCU
            flash_limit: 524288
          - project: DASH
            flash_limit: 2097152
          - project: LVPDB
            flash_limit: 524288
          - project: DART
            flash_limit: 32768
          - project: DCU
            flash_limit: 524288
          - project: DCU_Receiver
            flash_limit: 524288
          - project: Sensor_Nodes_FRONT
            flash_limit: 524288
          - project: Sensor_Nodes_REAR
            flash_limit: 524288
          - project: UART
            flash_limit: 524288
          - project: UART_TEST
            flash_limit: 2097152

    name: Size ${{ matrix.project }}

    steps:
      - name: Checkout
        uses: actions/checkout@v6
        with:
          submodules: recursive

      - name: Resolve source dir
        id: resolve
        run: |
          case "${{ matrix.project }}" in
            Sensor_Nodes_FRONT|Sensor_Nodes_REAR)
              echo "src_dir=Sensor_Nodes" >> "$GITHUB_OUTPUT"
              ;;
            *)
              echo "src_dir=${{ matrix.project }}" >> "$GITHUB_OUTPUT"
              ;;
          esac

      - name: Check buildability
        id: check
        run: |
          SRC="${{ steps.resolve.outputs.src_dir }}"
          if [ ! -f "${SRC}/CMakeLists.txt" ] || [ ! -d "${SRC}/Core" ]; then
            echo "skip=true" >> "$GITHUB_OUTPUT"
            echo "::warning::${{ matrix.project }} skipped -- missing ${SRC}/CMakeLists.txt or ${SRC}/Core/."
          else
            echo "skip=false" >> "$GITHUB_OUTPUT"
          fi

      - name: Install ARM GCC Toolchain
        if: steps.check.outputs.skip != 'true'
        uses: carlosperate/arm-none-eabi-gcc-action@v1
        with:
          release: '14.2.Rel1'

      - name: Install Ninja
        if: steps.check.outputs.skip != 'true'
        run: sudo apt-get install -y ninja-build

      - name: Configure CMake
        if: steps.check.outputs.skip != 'true'
        run: >
          cmake -S . -B build/${{ matrix.project }}
          -G Ninja
          -DCMAKE_BUILD_TYPE=Debug
          -DCMAKE_TOOLCHAIN_FILE=cmake/gcc-arm-none-eabi.cmake

      - name: Build
        if: steps.check.outputs.skip != 'true'
        run: cmake --build build/${{ matrix.project }} --target ${{ matrix.project }}

      - name: Measure firmware size
        if: steps.check.outputs.skip != 'true'
        id: size
        run: |
          ELF_PATH="build/${{ matrix.project }}/${{ steps.resolve.outputs.src_dir }}/${{ matrix.project }}.elf"

          # Get size output
          SIZE_OUTPUT=$(arm-none-eabi-size --format=berkeley "$ELF_PATH")
          echo "$SIZE_OUTPUT"

          # Parse individual sections
          TEXT=$(arm-none-eabi-size --format=berkeley "$ELF_PATH" | tail -1 | awk '{print $1}')
          DATA=$(arm-none-eabi-size --format=berkeley "$ELF_PATH" | tail -1 | awk '{print $2}')
          BSS=$(arm-none-eabi-size --format=berkeley "$ELF_PATH" | tail -1 | awk '{print $3}')

          # Calculate totals
          FLASH_USED=$((TEXT + DATA))
          RAM_USED=$((DATA + BSS))

          FLASH_LIMIT=${{ matrix.flash_limit }}
          USAGE_PERCENT=$(echo "scale=1; $FLASH_USED * 100 / $FLASH_LIMIT" | bc)

          echo "flash_used=$FLASH_USED" >> "$GITHUB_OUTPUT"
          echo "ram_used=$RAM_USED" >> "$GITHUB_OUTPUT"
          echo "usage_percent=$USAGE_PERCENT" >> "$GITHUB_OUTPUT"
          echo "text=$TEXT" >> "$GITHUB_OUTPUT"
          echo "data=$DATA" >> "$GITHUB_OUTPUT"
          echo "bss=$BSS" >> "$GITHUB_OUTPUT"

          # Format for display
          FLASH_USED_KB=$(echo "scale=1; $FLASH_USED / 1024" | bc)
          FLASH_LIMIT_KB=$(echo "scale=0; $FLASH_LIMIT / 1024" | bc)
          TEXT_KB=$(echo "scale=1; $TEXT / 1024" | bc)
          DATA_KB=$(echo "scale=1; $DATA / 1024" | bc)
          BSS_KB=$(echo "scale=1; $BSS / 1024" | bc)
          RAM_KB=$(echo "scale=1; $RAM_USED / 1024" | bc)

          echo "### ${{ matrix.project }} Firmware Size" >> "$GITHUB_STEP_SUMMARY"
          echo "" >> "$GITHUB_STEP_SUMMARY"
          echo "| Section | Size | Description |" >> "$GITHUB_STEP_SUMMARY"
          echo "|---------|------|-------------|" >> "$GITHUB_STEP_SUMMARY"
          echo "| .text | ${TEXT_KB} KB | Code (Flash) |" >> "$GITHUB_STEP_SUMMARY"
          echo "| .data | ${DATA_KB} KB | Initialized data (Flash + RAM) |" >> "$GITHUB_STEP_SUMMARY"
          echo "| .bss | ${BSS_KB} KB | Uninitialized data (RAM) |" >> "$GITHUB_STEP_SUMMARY"
          echo "| **Flash Total** | **${FLASH_USED_KB} KB / ${FLASH_LIMIT_KB} KB** | **${USAGE_PERCENT}%** |" >> "$GITHUB_STEP_SUMMARY"
          echo "| **RAM Total** | **${RAM_KB} KB** | data + bss |" >> "$GITHUB_STEP_SUMMARY"

      - name: Show largest symbols
        if: steps.check.outputs.skip != 'true'
        run: |
          ELF_PATH="build/${{ matrix.project }}/${{ steps.resolve.outputs.src_dir }}/${{ matrix.project }}.elf"

          echo "" >> "$GITHUB_STEP_SUMMARY"
          echo "#### Top 10 Largest Symbols" >> "$GITHUB_STEP_SUMMARY"
          echo "" >> "$GITHUB_STEP_SUMMARY"
          echo "\`\`\`" >> "$GITHUB_STEP_SUMMARY"
          arm-none-eabi-nm --size-sort --print-size --radix=d "$ELF_PATH" | tail -10 | tac >> "$GITHUB_STEP_SUMMARY"
          echo "\`\`\`" >> "$GITHUB_STEP_SUMMARY"

      - name: Check flash limits
        if: steps.check.outputs.skip != 'true'
        run: |
          FLASH_USED=${{ steps.size.outputs.flash_used }}
          FLASH_LIMIT=${{ matrix.flash_limit }}
          USAGE_PERCENT=${{ steps.size.outputs.usage_percent }}

          # Warning threshold: 90%
          WARNING_THRESHOLD=$(echo "$FLASH_LIMIT * 90 / 100" | bc)
          # Error threshold: 98%
          ERROR_THRESHOLD=$(echo "$FLASH_LIMIT * 98 / 100" | bc)

          if [ "$FLASH_USED" -gt "$ERROR_THRESHOLD" ]; then
            echo "::error::${{ matrix.project }} flash usage is critical: ${USAGE_PERCENT}% (>${{ matrix.flash_limit }} * 98%)"
            exit 1
          elif [ "$FLASH_USED" -gt "$WARNING_THRESHOLD" ]; then
            echo "::warning::${{ matrix.project }} flash usage is high: ${USAGE_PERCENT}% (>${{ matrix.flash_limit }} * 90%)"
          else
            echo "${{ matrix.project }} flash usage OK: ${USAGE_PERCENT}%"
          fi