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Fix flaky/hanging note-c card.binary HIL tests - #253

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fix/hil-host-mcu-usb-symlink-flicker
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Fix flaky/hanging note-c card.binary HIL tests#253
haydenroche5 wants to merge 1 commit into
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fix/hil-host-mcu-usb-symlink-flicker

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@haydenroche5 haydenroche5 commented Aug 11, 2026

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What

The note-c card.binary HIL job has been flaky — failing most nights, and in the last few it hung for hours. This fixes it.

Changes

  • Use the current notestation-client (v3.5.1) via the install_notestation_client action, replacing the old v2.2.0 client. The old one briefly flickered the Swan's USB test port while the board rebooted after flashing, so the tests couldn't open it and none ran.
  • Robust "start" handshake (after_upload.py): wait for the board's prompt, then send start a few times. A single start could be dropped while the USB settled (~2s), which left the run hung with no output.
  • Concurrency group so a new push cancels the previous run instead of two runs fighting over the single test station.
  • 30-minute job timeout so a stall fails fast instead of running for hours.
  • Dropped the "Install notecard CLI" and socat steps — the current client doesn't need them (a plain cat streams the trace).

Verified on barcelona-notestation-1: the suite reserves, flashes, and passes (16 tests) in ~7 min.

@haydenroche5
haydenroche5 force-pushed the fix/hil-host-mcu-usb-symlink-flicker branch from 9e7846c to 0923fc2 Compare August 11, 2026 16:27
@haydenroche5 haydenroche5 self-assigned this Aug 11, 2026
@haydenroche5
haydenroche5 force-pushed the fix/hil-host-mcu-usb-symlink-flicker branch from 2bd8879 to dadfdbb Compare August 11, 2026 22:24
@haydenroche5 haydenroche5 changed the title ci: use Go notestation-client to fix host_mcu_usb symlink flicker Fix flaky/hanging note-c card.binary HIL tests Aug 11, 2026
The nightly HIL job kept failing, and recently hung for hours. Fixes:

- Use the current notestation-client (v3.5.1) via the
  install_notestation_client action, replacing the old v2.2.0 client. The old
  one briefly flickered the Swan's USB test port while the board rebooted after
  flashing, so the tests couldn't open it and none ran.

- Wait for the board's prompt and send the "start" command a few times. The
  board can miss a single "start" sent while its USB is still settling (~2s),
  which left the run hung with no output.

- Add a concurrency group so a new push cancels the previous run instead of two
  runs fighting over the single test station.

- Cap the job at 30 minutes so a stall fails fast.

- Drop the "Install notecard CLI" and socat steps; the current client no longer
  needs them (a plain cat streams the Notecard trace).

Verified on barcelona-notestation-1.

Authored by Claude Code (AI agent).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
@haydenroche5
haydenroche5 force-pushed the fix/hil-host-mcu-usb-symlink-flicker branch from dadfdbb to 8f5928c Compare August 11, 2026 22:37
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