fix: open issue sweep and ESP32 v0.8.4 release

.github/workflows/firmware-ci.yml

@@ -52,22 +52,25 @@ jobs:
             target: esp32s3
             sdkconfig: sdkconfig.defaults
             partition_table_name: partitions_display.csv
-            size_limit_kb: 1100
+            size_warn_kb: 1100
+            size_limit_kb: 1152
             artifact_app: esp32-csi-node.bin
             artifact_pt: partition-table.bin
           - variant: 4mb
             target: esp32s3
             sdkconfig: sdkconfig.defaults.4mb
             partition_table_name: partitions_4mb.csv
-            size_limit_kb: 1100
+            size_warn_kb: 1100
+            size_limit_kb: 1152
             artifact_app: esp32-csi-node-4mb.bin
             artifact_pt: partition-table-4mb.bin
           # ADR-110: ESP32-C6 research target (Wi-Fi 6 / 802.15.4 / TWT / LP-core)
           - variant: c6-4mb
             target: esp32c6
             sdkconfig: sdkconfig.defaults
             partition_table_name: partitions_4mb.csv
-            size_limit_kb: 1100
+            size_warn_kb: 1100
+            size_limit_kb: 1152
             artifact_app: esp32-csi-node-c6.bin
             artifact_pt: partition-table-c6.bin
 
@@ -96,18 +99,23 @@ jobs:
           make test_adr110
           ./test_adr110
 
-      - name: Verify binary size (< ${{ matrix.size_limit_kb }} KB gate)
+      - name: Verify binary size budget
         working-directory: firmware/esp32-csi-node
         run: |
           BIN=build/esp32-csi-node.bin
           SIZE=$(stat -c%s "$BIN")
           MAX=$((${{ matrix.size_limit_kb }} * 1024))
+          WARN=$((${{ matrix.size_warn_kb }} * 1024))
           echo "Binary size: $SIZE bytes ($(( SIZE / 1024 )) KB)"
+          echo "Warning at:  $WARN bytes (${{ matrix.size_warn_kb }} KB)"
           echo "Size limit:  $MAX bytes (${{ matrix.size_limit_kb }} KB)"
           if [ "$SIZE" -gt "$MAX" ]; then
             echo "::error::Firmware binary exceeds ${{ matrix.size_limit_kb }} KB size gate ($SIZE > $MAX)"
             exit 1
           fi
+          if [ "$SIZE" -gt "$WARN" ]; then
+            echo "::warning::Firmware binary exceeds the ${{ matrix.size_warn_kb }} KB soft budget ($SIZE > $WARN); hard limit is ${{ matrix.size_limit_kb }} KB"
+          fi
           echo "Binary size OK: $SIZE <= $MAX"
 
       - name: Verify flash image integrity

CHANGELOG.md

@@ -11,10 +11,13 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 - **`@ruvnet/rvagent` startup optimization — stdio time-to-first-response ~242 ms → ~189 ms (−22%; MEASURED, median of repeated `initialize` round-trips against `dist/index.js`, this container, reproduce with a piped-stdin timer).** Two changes: (1) `./http-transport.js` is now imported **lazily** inside the `RVAGENT_HTTP_PORT` branch — it chain-loads the MCP SDK's `streamableHttp` module (~48 ms MEASURED via per-module `import()` timing), which the default stdio path never uses; (2) the advertised JSON Schemas generated from the Zod sources are memoized per tool instead of re-walking the Zod tree on every `tools/list` (matters under the session-per-server HTTP model where each session lists tools). No behavior change: 99/99 jest tests, HTTP session flow re-smoke-tested through the lazy path. The `@ruvnet/ruview` harness CLI was profiled too and left alone — 50 ms vs the ~29 ms bare `node -e ''` floor on the same box (MEASURED), i.e. already near the interpreter floor with zero dependencies.
 
 ### Fixed
+- **FastAPI health/metrics endpoints event-loop starvation.** Calling `psutil.cpu_percent(interval=1)` blocked the single-threaded async event loop for 1.0 second on every health check or metrics collection tick, stalling all incoming requests and WebSocket operations. Fixed by changing `cpu_percent` to use non-blocking `interval=None` and offloading all blocking OS metrics gathering to background thread pools via `asyncio.to_thread`. Verified event loop responsiveness via concurrency regression tests.
 - **EngineBridge now honors `WDP_GUARD_INTERVAL_US`/`WDP_SOFT_GUARD_US`/`WDP_TDM_SLOTS`+`WDP_TDM_SLOT_US`** (#1309, PR #1312, @erichkusuki). The governed trust path previously built its multistatic fuser from a hardcoded `MultistaticConfig::default()` (60 ms guard), so multi-node deployments with WiFi/ESP-NOW time sync (10–150 ms drift) failed every governed cycle regardless of configuration — while the startup log claimed the override took effect. New `StreamingEngine::set_multistatic_config()`; `EngineBridge::new()` takes an `Option<MultistaticConfig>` threaded from the same env-derived config as `AppState.multistatic_fuser`. Hardware-verified on a live 2-node ESP32-S3 setup (90 s window, 0 fusion errors; previously every cycle failed).
 - **`/api/v1/stream/pose` WebSocket reachable with `RUVIEW_API_TOKEN` set + dashboard bearer-token field** (#1310, PR #1313, @erichkusuki). Browsers cannot attach an `Authorization` header to a WS upgrade, so the Live Demo pose stream always failed when auth was on; the path is now on a narrow exact-match exemption list (mirrors `/ws/sensing`), with a regression test pinning that the exemption doesn't leak to other `/api/v1/*` paths. The QuickSettings panel gains an "API Access" field storing the bearer token in `localStorage`; the token is applied at `api.service.js` module load so the very first request carries it.
 - **Display-less DevKitC-1 boards: `sdkconfig.defaults.devkitc` build overlay** (#1308, PR #1311, @erichkusuki). The ADR-045 runtime display probe false-positives on stock ESP32-S3-DevKitC-1 (floating QSPI pins), which silently skipped the RuView#893 MGMT+DATA CSI upgrade and collapsed CSI yield to 0 pps. The overlay compiles display support out (`has_display` constant-false). Also fixes stale `espressif/idf:v5.2` README references to v5.4 (source requires `esp_driver_uart`, IDF ≥5.3). Hardware-verified on 2× DevKitC-1-N16R8 (0 → 40–45 pps).
 - **ADR-263/264/265 implemented — the RuView npm surface fixed end-to-end (`@ruvnet/ruview@0.2.0`, `@ruvnet/rvagent@0.2.0`, `@ruv/ruview-cli`).** Harness (ADR-263 O1–O9): `claim-check` now **fails closed** on empty input (CLI exit 2 + `empty_text` tool error); the MCP stdio server dispatches `tools/call` asynchronously over promise-based `spawn` — `ping` answers while a long `verify`/`calibrate` runs (pinned by a new e2e test that runs a 3 s fake proof and asserts sub-second ping); the two `optionalDependencies` are gone so a cold `npx` installs exactly 1 package (MEASURED: was 4 packages / 620 kB / 71 files, `npm i` in a clean prefix); child output is captured as bounded rolling tails (no more 1 MiB `maxBuffer` kills); `node_monitor` passes the port via `sys.argv` instead of splicing it into `python -c` source; the MCP `serverInfo.version` reads package.json; `.claude/skills/*/SKILL.md` are generated from `skills/*.md` by a `prepack` sync script (byte-equality pinned by test); `which()` is a memoized dep-free PATH scan; tools are underscore-canonical (`ruview_claim_check`, …) with the dotted names accepted as call-time aliases, plus `resources/list`/`prompts/list` stubs; the guardrail's `METRIC_TERMS` matching is precision-fixed (word-boundary `map`/`f1`/`auc`/`iou`, code-span + label scrubbing, quantitative-claims-only) — ADR-263/264/265 and both package READMEs now PASS `claim-check` while real untagged claims still flag. 30/30 tests (MEASURED, `node --test`). rvagent (ADR-264 O1–O9): `exports` fixed (types-first, the never-built `dist/index.cjs` `require` target removed — verified broken in the published 0.1.0 tarball); tarball is map-free (127,704 B unpacked / 46 files / 0 maps — MEASURED, `npm pack --dry-run`, down from 188 kB with 44 maps); the Streamable HTTP transport is **actually wired** behind `RVAGENT_HTTP_PORT` with one transport + one MCP server per session (`mcp-session-id` routing), a 1 MiB body cap (413), and a port-aware localhost origin gate — the "dual-transport" description is now true; tools renamed to underscore-canonical with dotted router aliases; ONE Zod validation gate per call with the advertised JSON Schema generated from the same Zod source (`zod-to-json-schema`); `train_count` closes its log fds (was leaking 2/job) and persists job records to `<jobsDir>/<id>.json` so `job_status` survives restarts, with bounded log-tail reads; `detectCogBinary` actually probes its candidate paths; version reads package.json; `@types/express` dropped, `@types/jest` aligned to jest 29; README rewritten to match reality (no phantom `stdio`/`http`/`policy grant` subcommands; unimplemented ADR-124 catalog tools labeled roadmap). 99/99 jest tests (MEASURED); stdio handshake + HTTP session flow + 403/400/404/413 gates smoke-tested live. CLI: bin renamed `ruview-cli` (the `ruview` bin belongs to `@ruvnet/ruview`, ADR-265 D4), version single-sourced. Distribution (ADR-265 D1–D4): new `npm-packages.yml` (3-package × Node 20/22 matrix: tests, version-literal grep gate, pack-content/size gate, tarball-install smoke test incl. the fail-closed claim-check and an ESM-import probe that would have caught the broken `require` export, README claim-check) and `ruview-npm-release.yml` (publish from CI only, `npm publish --provenance`); `ci.yml` NODE_VERSION 18→20.
+- **Empty-room field-model calibration collected nothing on real HT40 nodes — raw 128-wide frames rejected by the 56-tone model (follow-up to the deadlock fix below).** Once the status-gate deadlock was fixed, `maybe_feed_calibration` reached `feed_calibration`, but a real ESP32 HT40 node streams 128-wide amplitude vectors while the single-link `FieldModel` is the canonical 56-tone grid — so `LinkStats::update` returned `DimensionMismatch`, `feed_calibration` bubbled the error, and `maybe_feed_calibration` swallowed it at `debug` level. Net effect: `frame_count` stayed pinned at 0 on live hardware even though presence/motion/vitals (which read the global history) worked fine. Fixed by resampling each frame onto the model's canonical 56-tone grid via `HardwareNormalizer::resample_to_canonical` before feeding — the same length-only canonicalization the multistatic fusion path uses (#1170). Pinned by `field_bridge::maybe_feed_calibration_resamples_wide_frames_and_accumulates` (128-wide frame → Collecting + count 1; fails on old code). Verified live on the ESP32-S3 deployment.
+- **Empty-room field-model calibration could never start — `/api/v1/calibration/*` was a dead endpoint (frame count pinned at 0).** `POST /calibration/start` creates the `FieldModel` in `Uncalibrated`, but the per-frame server feed `field_bridge::maybe_feed_calibration` only fed observations while the model was **already** `Collecting` — and the *only* thing that sets `Collecting` is `feed_calibration` itself (on its first fed frame). The two gates deadlocked: nothing ever fed the first frame, so `calibration_frame_count` stayed 0, `status` never left `Uncalibrated`, and the SVD room eigenstructure (eigenvalue-based person counting / localization) could never calibrate — observed live as `{"status":"Uncalibrated","frame_count":0}` never advancing on a streaming ESP32 node. Fixed the guard to feed while `Uncalibrated | Collecting` so the first frame flips the model to `Collecting` and the count advances. Also made `calibration_stop` return a structured `{success:false, frame_count, frames_needed}` (with a new `FieldModel::min_calibration_frames()` accessor) instead of an opaque 500 when finalized before enough empty-room frames accumulate. Pinned by `field_bridge::maybe_feed_calibration_advances_uncalibrated_to_collecting` (asserts `Uncalibrated → Collecting` + count 0 → 1 → 2; fails on old code). Presence/motion/vitals were unaffected — they use the separate auto rolling baseline, not the field model.
 - **Multistatic fusion never ran on a mixed-mode ESP32 mesh — live bridge fed raw, un-canonicalized per-node CSI to the fuser (#1170).** `node_frame_from_state` (`multistatic_bridge.rs`) wrapped each node's **raw** amplitude vector (HT20 ≈ 64 bins, HT40 ≈ 128/192) into a struct *named* `CanonicalCsiFrame` without ever resampling, so `MultistaticFuser::fuse` tripped `DimensionMismatch` on every cycle, silently fell back to per-node sum/dedup, and spun `total_engine_errors` unbounded. Added `HardwareNormalizer::resample_to_canonical` (resample-only, **no z-score** — preserves the amplitude scale the person-score's `variance/mean²` relies on) and run every node frame through it onto the canonical 56-tone grid before fusion. Heterogeneous meshes now fuse instead of erroring. Pinned by `heterogeneous_node_counts_canonicalize_and_fuse` (mixed 64/192 → fuses), `resample_to_canonical_is_length_only_no_zscore`, and an updated `test_node_frame_conversion`; the pre-existing `engine_bridge::observe_cycle_counts_engine_errors` was retargeted to force a `TimestampMismatch` (its old 56-vs-30 setup now canonicalizes cleanly). `wifi-densepose-signal` 501 / `wifi-densepose-sensing-server` 677 tests, 0 failed.
 - **`csi_fps_ema` reported the CSI frame rate 40–840× too high under bursty UDP delivery (#1180).** `update_csi_fps_ema` only rejected deltas `≤ 0` or `≥ 1 s`, so a 36 µs intra-burst arrival delta yielded `1/dt ≈ 27 kHz` straight into the EMA — the metric measured server arrival jitter, not the node's ~40 fps production rate. Added a `MIN_PLAUSIBLE_CSI_DT_SEC = 0.005` floor (derived from the firmware's 50 fps `CSI_MIN_SEND_INTERVAL_US` ceiling, ×4 slack) and made `observe_csi_frame_arrival` keep its anchor across sub-floor bursts so the next genuine inter-frame gap measures true cadence. Pinned by `subms_burst_delta_rejected`, `burst_interleaved_with_nominal_stays_in_band`, and `observe_csi_frame_arrival_ignores_subms_bursts`.
 - **`stream_sender` ENOMEM backoff starved low-rate control packets under a weak uplink (#1183, follow-up to #1135/#1159).** The global `s_backoff_until_us` gate (triggered by the 50 Hz CSI flood at weak RSSI) also suppressed the ≤48 B, ≤1 Hz `feature_state` / mesh `HEALTH` / sync packets that contribute negligible buffer pressure, so telemetry failed essentially every cycle. Added `stream_sender_send_priority()` — bypasses the backoff gate, reports ENOMEM quietly, and never extends/resets the global streak — and routed `feature_state`, HEALTH/anomaly (`rv_mesh_send`), and sync packets through it. Also fixed the misleading `"HEALTH sent"` log that printed unconditionally even when `rv_mesh_send` returned `ESP_FAIL` (now prints `sent`/`FAILED` from the actual return). Firmware builds clean (ESP-IDF v5.4).

CLAUDE.md

@@ -93,6 +93,8 @@ All 5 ruvector crates integrated in workspace:
 
 **Not supported:** ESP32 (original), ESP32-C3 — single-core, can't run CSI DSP pipeline.
 
+**⚠️ Compact boards (SuperMini, ESP32-S3-Zero, other coin-sized clones) run hot:** the firmware keeps the WiFi radio on continuously (`WIFI_PS_NONE`) and runs a full DSP pipeline (`edge_tier=2`), which is sustained high current draw. Full-size dev boards handle this fine; coin-sized clones with minimal PCB copper and budget regulators can run uncomfortably hot and, per at least one field report, have failed to power on again after a hot session. Give them airflow and check by touch during the first few minutes. See `firmware/esp32-csi-node/README.md` for details.
+
 ### Build & Test Commands (this repo)
 ```bash
 # Rust — full workspace tests (1,031+ tests, ~2 min)

archive/v1/src/api/routers/health.py

@@ -2,6 +2,7 @@
 Health check API endpoints
 """
 
+import asyncio
 import logging
 import psutil
 from typing import Dict, Any, Optional
@@ -168,7 +169,7 @@ async def health_check(request: Request):
             overall_status = "degraded"
 
         # Get system metrics
-        system_metrics = get_system_metrics()
+        system_metrics = await asyncio.to_thread(get_system_metrics)
 
         uptime_seconds = (datetime.now() - _APP_START_TIME).total_seconds()
 
@@ -263,11 +264,12 @@ async def get_health_metrics(
 ):
     """Get detailed system metrics."""
     try:
-        metrics = get_system_metrics()
+        metrics = await asyncio.to_thread(get_system_metrics)
 
         # Add additional metrics if authenticated
         if current_user:
-            metrics.update(get_detailed_metrics())
+            detailed = await asyncio.to_thread(get_detailed_metrics)
+            metrics.update(detailed)
 
         return {
             "timestamp": datetime.utcnow().isoformat(),
@@ -300,7 +302,7 @@ def get_system_metrics() -> Dict[str, Any]:
     """Get basic system metrics."""
     try:
         # CPU metrics
-        cpu_percent = psutil.cpu_percent(interval=1)
+        cpu_percent = psutil.cpu_percent(interval=None)
         cpu_count = psutil.cpu_count()
 
         # Memory metrics

archive/v1/src/services/metrics.py

@@ -180,21 +180,24 @@ async def collect_metrics(self):
     async def _collect_system_metrics(self):
         """Collect system-level metrics."""
         try:
-            # CPU usage
-            cpu_percent = psutil.cpu_percent(interval=1)
-            self._metrics["system_cpu_usage"].add_point(cpu_percent)
+            # Query OS metrics in a background thread to prevent blocking the event loop
+            def gather_metrics():
+                return (
+                    psutil.cpu_percent(interval=None),
+                    psutil.virtual_memory().percent,
+                    psutil.disk_usage('/'),
+                    psutil.net_io_counters()
+                )
+
+            cpu_percent, mem_percent, disk, network = await asyncio.to_thread(gather_metrics)
 
-            # Memory usage
-            memory = psutil.virtual_memory()
-            self._metrics["system_memory_usage"].add_point(memory.percent)
+            # Record metrics on the main loop
+            self._metrics["system_cpu_usage"].add_point(cpu_percent)
+            self._metrics["system_memory_usage"].add_point(mem_percent)
 
-            # Disk usage
-            disk = psutil.disk_usage('/')
             disk_percent = (disk.used / disk.total) * 100
             self._metrics["system_disk_usage"].add_point(disk_percent)
 
-            # Network I/O
-            network = psutil.net_io_counters()
             self._metrics["system_network_bytes_sent"].add_point(network.bytes_sent)
             self._metrics["system_network_bytes_recv"].add_point(network.bytes_recv)
 

archive/v1/tests/unit/test_health_concurrency.py

@@ -0,0 +1,59 @@
+import asyncio
+import time
+import os
+import sys
+
+import pytest
+
+# Add project root and archive/v1 to sys.path so we can import src modules
+sys.path.append(os.path.abspath(os.path.join(os.path.dirname(__file__), "../../../../")))
+sys.path.append(os.path.abspath(os.path.join(os.path.dirname(__file__), "../../")))
+
+from archive.v1.src.api.routers.health import get_system_metrics
+
+async def ticker():
+    """Asynchronous background ticker to measure event loop latency/freezes."""
+    ticks = []
+    for _ in range(15):
+        ticks.append(time.time())
+        await asyncio.sleep(0.1)
+    return ticks
+
+async def run_test():
+    print("Starting concurrency verification test...")
+
+    # Start the ticker background task
+    ticker_task = asyncio.create_task(ticker())
+
+    # Let ticker run for a few ticks
+    await asyncio.sleep(0.3)
+
+    print("Calling get_system_metrics offloaded to background thread...")
+    start_time = time.time()
+
+    # Query system metrics using to_thread (simulating FastAPI request)
+    metrics = await asyncio.to_thread(get_system_metrics)
+
+    duration = time.time() - start_time
+    print(f"get_system_metrics took: {duration:.4f}s")
+
+    # Wait for the ticker to complete
+    ticks = await ticker_task
+
+    # Calculate gaps between consecutive ticks to check for event loop freezes
+    gaps = [ticks[i+1] - ticks[i] for i in range(len(ticks)-1)]
+    max_gap = max(gaps)
+
+    print(f"All tick gaps: {[round(g, 3) for g in gaps]}")
+    print(f"Max event loop freeze: {max_gap:.4f}s")
+
+    # In pre-fix code, psutil.cpu_percent(interval=1) blocks for 1.0s,
+    # causing a gap of >1.0s. With our fix, it should be close to 0.1s.
+    return max_gap, duration
+
+@pytest.mark.asyncio
+async def test_get_system_metrics_does_not_starve_event_loop():
+    max_gap, duration = await run_test()
+    # ticker sleeps 0.1s; allow slack for CI, but we should not see ~1s gaps
+    assert max_gap < 0.6
+    assert duration < 0.6