Add async firmware cache clearing for multi-bond support #123

Workflow file for this run

	name: Build & Release

	on:
	push:
	branches: [ main ]
	pull_request:
	branches: [ main ]
	workflow_dispatch:
	inputs:
	bump_version:
	description: 'Create Release'
	required: false
	default: 'none'
	type: choice
	options:
	- none
	- patch
	- minor
	- major

	jobs:
	# Bump version if requested (only for workflow_dispatch)
	bump-version:
	if: github.event_name == 'workflow_dispatch' && github.event.inputs.bump_version != 'none'
	runs-on: ubuntu-latest
	permissions:
	contents: write
	outputs:
	version_bumped: ${{ steps.bump.outputs.bumped }}

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4
	with:
	fetch-depth: 0

	- name: Bump version
	id: bump
	run: \|
	CURRENT_VERSION=$(cat VERSION \| tr -d '[:space:]')
	echo "Current version: $CURRENT_VERSION"

	# Parse version (assuming semver X.Y.Z)
	IFS='.' read -r MAJOR MINOR PATCH <<< "$CURRENT_VERSION"

	case "${{ github.event.inputs.bump_version }}" in
	patch)
	PATCH=$((PATCH + 1))
	;;
	minor)
	MINOR=$((MINOR + 1))
	PATCH=0
	;;
	major)
	MAJOR=$((MAJOR + 1))
	MINOR=0
	PATCH=0
	;;
	esac

	NEW_VERSION="${MAJOR}.${MINOR}.${PATCH}"
	echo "New version: $NEW_VERSION"
	echo "$NEW_VERSION" > VERSION
	echo "new_version=$NEW_VERSION" >> $GITHUB_OUTPUT
	echo "bumped=true" >> $GITHUB_OUTPUT

	- name: Commit and push version bump
	uses: stefanzweifel/git-auto-commit-action@v5
	with:
	commit_message: "Bump version to ${{ steps.bump.outputs.new_version }}"
	file_pattern: VERSION
	commit_user_name: ${{ github.actor }}
	commit_user_email: ${{ github.actor }}@users.noreply.github.com
	commit_author: ${{ github.actor }} <${{ github.actor }}@users.noreply.github.com>

	# Check if VERSION has a release tag (determines if we should build/release)
	check-version-tag:
	needs: [bump-version]
	if: always()
	runs-on: ubuntu-latest
	outputs:
	version: ${{ steps.version.outputs.version }}
	has_release: ${{ steps.check.outputs.has_release }}

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4
	with:
	fetch-depth: 0
	ref: main # Always fetch latest main to get version bump commit

	- name: Read VERSION file
	id: version
	run: \|
	VERSION=$(cat VERSION \| tr -d '[:space:]')
	echo "version=${VERSION}" >> $GITHUB_OUTPUT
	echo "📦 Current VERSION: ${VERSION}"

	- name: Check if version tag exists
	id: check
	run: \|
	VERSION="${{ steps.version.outputs.version }}"

	# Check if tag exists (locally or remotely)
	if git rev-parse "v${VERSION}" >/dev/null 2>&1; then
	echo "has_release=true" >> $GITHUB_OUTPUT
	echo "⏭️ Version v${VERSION} already has a release"
	else
	echo "has_release=false" >> $GITHUB_OUTPUT
	echo "✅ Version v${VERSION} does not have a release - will build & release"
	fi

	# Always run security scan
	check-security:
	needs: [bump-version]
	if: always()
	runs-on: ubuntu-latest

	steps:
	- name: Checkout code
	uses: actions/checkout@v4

	- name: Run security scan
	run: \|
	echo "Running security analysis..."
	# Check for common security issues in C code
	find ncs/app/src -name '.c' -o -name '.h' \| xargs grep -l 'strcpy\\|sprintf\\|gets' \|\| echo 'No obvious security issues found'

	# Check which directories changed
	check-changes:
	needs: [bump-version]
	if: always()
	runs-on: ubuntu-latest
	outputs:
	ncs_changed: ${{ steps.changes.outputs.ncs }}
	esp_changed: ${{ steps.changes.outputs.esp }}
	version_changed: ${{ steps.changes.outputs.version }}

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4
	with:
	fetch-depth: 0
	ref: main # Always fetch latest main to get version bump commit

	- name: Check for file changes
	id: changes
	run: \|
	# If version was bumped by workflow, mark version as changed
	if [ "${{ needs.bump-version.outputs.version_bumped }}" = "true" ]; then
	echo "version=true" >> $GITHUB_OUTPUT
	echo "✅ VERSION bumped by workflow - will build all firmware"
	else
	# For PRs, compare against base branch
	if [ "${{ github.event_name }}" = "pull_request" ]; then
	BASE_SHA="${{ github.event.pull_request.base.sha }}"
	HEAD_SHA="${{ github.event.pull_request.head.sha }}"
	else
	# For pushes, compare with previous commit
	BASE_SHA="${{ github.event.before }}"
	HEAD_SHA="${{ github.sha }}"
	fi

	echo "Comparing $BASE_SHA...$HEAD_SHA"

	# Check if VERSION file changed
	if git diff --name-only $BASE_SHA $HEAD_SHA \| grep -q '^VERSION$'; then
	echo "version=true" >> $GITHUB_OUTPUT
	echo "✅ VERSION file changed - will build all firmware"
	else
	echo "version=false" >> $GITHUB_OUTPUT
	echo "⏭️ VERSION file unchanged"
	fi
	fi

	# Check if ncs directory changed
	if git diff --name-only $BASE_SHA $HEAD_SHA \| grep -q '^ncs/'; then
	echo "ncs=true" >> $GITHUB_OUTPUT
	echo "✅ ncs/ directory has changes"
	else
	echo "ncs=false" >> $GITHUB_OUTPUT
	echo "⏭️ ncs/ directory unchanged"
	fi

	# Check if esp directory changed
	if git diff --name-only $BASE_SHA $HEAD_SHA \| grep -q '^esp/'; then
	echo "esp=true" >> $GITHUB_OUTPUT
	echo "✅ esp/ directory has changes"
	else
	echo "esp=false" >> $GITHUB_OUTPUT
	echo "⏭️ esp/ directory unchanged"
	fi

	# Build nRF52 firmware
	build-nrf52:
	needs: [check-security, check-changes, check-version-tag]
	# Build if: VERSION file changed OR ncs directory changed OR VERSION doesn't have a release
	if: always() && (needs.check-changes.outputs.version_changed == 'true' \|\| needs.check-changes.outputs.ncs_changed == 'true' \|\| needs.check-version-tag.outputs.has_release == 'false')
	runs-on: ubuntu-latest
	container:
	image: ghcr.io/zephyrproject-rtos/ci:v0.26.6
	env:
	CMAKE_PREFIX_PATH: /opt/toolchains
	strategy:
	matrix:
	board: [seeed_xiao_nrf52840, adafruit_feather_nrf52840, nordic_nrf52840dongle, aprbrother_nrf52840, raytac_mdbt50q_rx, raytac_mdbt50q_cx_40, makerdiary_nrf52840mdk]
	include:
	- board: seeed_xiao_nrf52840
	description: "Seeed XIAO nRF52840"
	board_target: xiao_ble
	overlay: seeed_xiao_nrf52840.overlay
	conf: seeed_xiao_nrf52840.conf
	- board: adafruit_feather_nrf52840
	description: "Adafruit Feather nRF52840 Express"
	board_target: adafruit_feather_nrf52840
	- board: nordic_nrf52840dongle
	description: "Nordic nRF52840 Dongle (PCA10059)"
	board_target: nrf52840dongle
	overlay: nordic_nrf52840dongle.overlay
	conf: nordic_nrf52840dongle.conf
	- board: aprbrother_nrf52840
	description: "April Brother nRF52840 Dongle"
	board_target: nrf52840dongle
	overlay: aprbrother_nrf52840.overlay
	conf: aprbrother_nrf52840.conf
	- board: raytac_mdbt50q_rx
	description: "Raytac MDBT50Q-RX Dongle"
	board_target: nrf52840dongle
	overlay: raytac_mdbt50q_rx.overlay
	conf: raytac_mdbt50q_rx.conf
	- board: raytac_mdbt50q_cx_40
	description: "Raytac MDBT50Q-CX-40 (Nordic DFU)"
	board_target: raytac_mdbt50q_cx_40/nrf52840
	overlay: raytac_mdbt50q_cx_40.overlay
	conf: raytac_mdbt50q_cx_40.conf
	uses_dfu: true
	- board: makerdiary_nrf52840mdk
	description: "MakerDiary nRF52840 MDK USB Dongle"
	board_target: nrf52840dongle
	overlay: makerdiary_nrf52840mdk.overlay
	conf: makerdiary_nrf52840mdk.conf

	steps:
	- uses: actions/checkout@v4
	with:
	submodules: recursive
	ref: main # Always fetch latest main to get version bump commit

	- name: 💾 Cache Zephyr Workspace
	id: cache-workspace
	uses: actions/cache@v4
	with:
	path: /zephyr_workspace
	key: zephyr-workspace-ncs-v3.1.0-${{ runner.os }}
	restore-keys: \|
	zephyr-workspace-ncs-v3.1.0-

	- name: ♻️ Initialize Zephyr Workspace
	if: steps.cache-workspace.outputs.cache-hit != 'true'
	run: \|
	mkdir -p /zephyr_workspace
	cd /zephyr_workspace
	west init -m https://github.com/nrfconnect/sdk-nrf.git --mr v3.1.0
	west update --narrow -o=--depth=1

	- name: 📁 Copy App and Board Files to Workspace
	run: \|
	rm -rf /zephyr_workspace/app
	rm -rf /zephyr_workspace/build
	# Create app directory structure matching local layout
	mkdir -p /zephyr_workspace/ncs
	cp -r ncs/app /zephyr_workspace/ncs/app
	cp VERSION /zephyr_workspace/VERSION
	# Symlink for compatibility with build commands
	ln -s /zephyr_workspace/ncs/app /zephyr_workspace/app

	- name: 💾 Cache ccache
	uses: actions/cache@v4
	with:
	path: ~/.cache/ccache
	key: ccache-v1-${{ runner.os }}-${{ matrix.board }}-${{ github.sha }}
	restore-keys: \|
	ccache-v1-${{ runner.os }}-${{ matrix.board }}-
	ccache-v1-${{ runner.os }}-

	- name: 🔨 Build Project
	run: \|
	cd /zephyr_workspace
	ccache -z

	# Build with overlay/conf if specified, otherwise use board defaults
	if [ -n "${{ matrix.overlay }}" ]; then
	echo "Building ${{ matrix.description }} with custom overlay/conf"
	west build \
	--board ${{ matrix.board_target }} \
	--pristine=always app \
	-- \
	-DBOARD_ROOT="/zephyr_workspace/ncs/app" \
	-DDTC_OVERLAY_FILE="/zephyr_workspace/ncs/app/boards/${{ matrix.overlay }}" \
	-DEXTRA_CONF_FILE="/zephyr_workspace/ncs/app/boards/${{ matrix.conf }}"
	else
	echo "Building ${{ matrix.description }} with board defaults"
	west build \
	--board ${{ matrix.board_target }} \
	--pristine=always app \
	-- \
	-DBOARD_ROOT="/zephyr_workspace/ncs/app"
	fi

	ccache -sv

	- name: 📦 Prepare Firmware Artifacts
	run: \|
	cd /zephyr_workspace

	# Always use version from check-version-tag
	FILENAME_VERSION="${{ needs.check-version-tag.outputs.version }}"

	# Clean up any old firmware files from cached workspace
	rm -f mp_usb_.uf2 mp_usb_.zip mp_usb_*.hex

	# Check if this board uses DFU (Nordic bootloader)
	if [ "${{ matrix.uses_dfu }}" = "true" ]; then
	echo "📦 Creating DFU package for ${{ matrix.board }}..."
	# Install nrfutil if not present
	pip3 install --user nrfutil >/dev/null 2>&1 \|\| true
	# Create DFU package for command-line flashing (application-version must be integer)
	~/.local/bin/nrfutil pkg generate --hw-version 52 --sd-req 0x00 \
	--application-version 1 \
	--application build/app/zephyr/zephyr.hex \
	mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.zip
	# Also copy HEX file for nRF Connect for Desktop Programmer (GUI)
	cp build/app/zephyr/zephyr.hex mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.hex
	echo "✅ ${{ matrix.board }} DFU ZIP: mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.zip"
	echo "✅ ${{ matrix.board }} HEX: mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.hex"
	else
	# Copy and rename UF2 files
	cp build/app/zephyr/zephyr.uf2 mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.uf2
	echo "✅ ${{ matrix.board }} UF2: mp_usb_${FILENAME_VERSION}_${{ matrix.board }}.uf2"
	fi

	ls -la mp_usb_*

	- name: 📦 Upload Firmware Artifact
	uses: actions/upload-artifact@v4
	with:
	name: mp_usb_${{ matrix.board }}
	path: /zephyr_workspace/mp_usb_*
	retention-days: 90

	# Build ESP32 firmware
	build-esp32:
	needs: [check-security, check-changes, check-version-tag]
	# Build if: VERSION file changed OR esp directory changed OR VERSION doesn't have a release
	if: always() && (needs.check-changes.outputs.version_changed == 'true' \|\| needs.check-changes.outputs.esp_changed == 'true' \|\| needs.check-version-tag.outputs.has_release == 'false')
	runs-on: ubuntu-latest
	strategy:
	matrix:
	board:
	- name: seeed_xiao_esp32s3
	display_name: "Seeed XIAO ESP32-S3"
	sdkconfig: "sdkconfig.defaults;sdkconfig.board.xiao"
	- name: lilygo_tdisplay_s3
	display_name: "LilyGo T-Display-S3"
	sdkconfig: "sdkconfig.defaults;sdkconfig.board.lilygo"

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4
	with:
	submodules: recursive
	ref: main # Always fetch latest main to get version bump commit

	- name: Build ${{ matrix.board.display_name }}
	uses: espressif/esp-idf-ci-action@v1
	with:
	esp_idf_version: release-v6.0
	target: esp32s3
	path: esp
	command: \|
	. ~/esp-idf/export.sh
	cd esp
	export SDKCONFIG_DEFAULTS="${{ matrix.board.sdkconfig }}"
	idf.py build

	- name: Prepare artifacts
	run: \|
	mkdir -p artifacts

	# Always use version from check-version-tag
	FILENAME_VERSION="${{ needs.check-version-tag.outputs.version }}"

	# Copy app binary only (preserves NVS/BLE bonds when flashed at 0x10000)
	cp esp/build/mouthpad_usb.bin artifacts/mp_usb_${FILENAME_VERSION}_${{ matrix.board.name }}.bin

	echo "✅ ${{ matrix.board.display_name }} app binary created"
	ls -lh artifacts/

	- name: Upload firmware artifacts
	uses: actions/upload-artifact@v4
	with:
	name: mp_usb_${{ matrix.board.name }}
	path: artifacts/mp_usb_*.bin
	if-no-files-found: error
	retention-days: 90

	# Create release (only if version tag doesn't exist yet)
	create-release:
	needs: [build-nrf52, build-esp32, check-version-tag]
	if: always() && needs.check-version-tag.outputs.has_release == 'false' && (needs.build-nrf52.result == 'success' \|\| needs.build-nrf52.result == 'skipped') && (needs.build-esp32.result == 'success' \|\| needs.build-esp32.result == 'skipped')
	runs-on: ubuntu-latest
	permissions:
	contents: write

	steps:
	- name: Checkout repository
	uses: actions/checkout@v4

	- name: Download all artifacts
	uses: actions/download-artifact@v4
	with:
	path: artifacts

	- name: Prepare release package
	run: \|
	mkdir -p release
	VERSION="${{ needs.check-version-tag.outputs.version }}"

	echo "📦 Collecting firmware files for v${VERSION} release:"

	# Copy all firmware files from artifacts
	find artifacts -type f $ -name ".uf2" -o -name ".bin" -o -name ".zip" -o -name ".hex" $ -exec cp {} release/ \;

	echo ""
	echo "✅ Release package contents:"
	ls -lh release/

	# Create checksums
	cd release
	sha256sum * > checksums.txt
	echo ""
	echo "🔐 Checksums:"
	cat checksums.txt

	- name: Create GitHub Release
	uses: softprops/action-gh-release@v1
	with:
	tag_name: v${{ needs.check-version-tag.outputs.version }}
	name: MouthPad USB v${{ needs.check-version-tag.outputs.version }}
	body: \|
	## MouthPad USB Firmware v${{ needs.check-version-tag.outputs.version }}

	### 📦 Firmware Files

	nRF52840 Boards (UF2 format - drag & drop to bootloader):
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_seeed_xiao_nrf52840.uf2` - Seeed XIAO nRF52840
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_adafruit_feather_nrf52840.uf2` - Adafruit Feather nRF52840 Express
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_nordic_nrf52840dongle.uf2` - Nordic nRF52840 Dongle
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_aprbrother_nrf52840.uf2` - April Brother nRF52840 Dongle
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_raytac_mdbt50q_rx.uf2` - Raytac MDBT50Q-RX Dongle
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_makerdiary_nrf52840mdk.uf2` - MakerDiary nRF52840 MDK USB Dongle

	nRF52840 Boards (Nordic DFU bootloader - Raytac CX-40):
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_raytac_mdbt50q_cx_40.hex` - HEX file (for nRF Connect Programmer GUI)
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_raytac_mdbt50q_cx_40.zip` - DFU package (for command-line nrfutil)

	ESP32-S3 Boards (BIN format - flash with esptool):
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_seeed_xiao_esp32s3.bin` - Seeed XIAO ESP32-S3
	- `mp_usb_${{ needs.check-version-tag.outputs.version }}_lilygo_tdisplay_s3.bin` - LilyGo T-Display-S3

	### 🔧 Installation

	nRF52840 (UF2 - most boards):
	1. Enter bootloader mode (double-tap reset button)
	2. Drag & drop the `.uf2` file to the mounted drive
	3. Device will automatically reboot with new firmware

	nRF52840 (Nordic DFU for Raytac CX-40):

	Option 1 - GUI with HEX file (Recommended):
	1. Download [nRF Connect for Desktop](https://www.nordicsemi.com/Products/Development-tools/nRF-Connect-for-Desktop)
	2. Install the "Programmer" app
	3. Put device in bootloader mode (hold RESET button while connecting USB)
	4. Select device in nRF Connect Programmer
	5. Add the `.hex` file and click "Write"

	Option 2 - Command Line with ZIP package:
	1. Install nrfutil: `pip install nrfutil`
	2. Put device in bootloader mode (hold RESET button while connecting USB)
	3. Flash: `nrfutil dfu serial -pkg mp_usb_<version>_raytac_mdbt50q_cx_40.zip -p <PORT>`
	4. Device will automatically reboot with new firmware

	ESP32-S3 (BIN):
	```bash
	esptool.py --chip esp32s3 write_flash 0x10000 mp_usb_<version>_<board>.bin
	```

	Note:
	- UF2 and DFU preserve Settings/NVS storage including BLE bonds
	- ESP32-S3: Flashing at 0x10000 (app partition) preserves NVS storage

	### 🔐 Checksums
	See `checksums.txt` for SHA256 verification.
	files: \|
	release/*
	draft: false
	prerelease: false
	env:
	GITHUB_TOKEN: ${{ secrets.GITHUB_TOKEN }}

	- name: Release Summary
	run: \|
	VERSION="${{ needs.check-version-tag.outputs.version }}"
	echo "### ✅ Release v${VERSION} Created" >> $GITHUB_STEP_SUMMARY
	echo "" >> $GITHUB_STEP_SUMMARY
	echo "Version: \`v${VERSION}\`" >> $GITHUB_STEP_SUMMARY
	echo "Firmware files: $(ls release/ \| grep -E '\.(uf2\|bin\|zip\|hex)$' \| wc -l)" >> $GITHUB_STEP_SUMMARY
	echo "" >> $GITHUB_STEP_SUMMARY
	echo "📦 Release contents:" >> $GITHUB_STEP_SUMMARY
	echo "\`\`\`" >> $GITHUB_STEP_SUMMARY
	ls -lh release/ >> $GITHUB_STEP_SUMMARY
	echo "\`\`\`" >> $GITHUB_STEP_SUMMARY

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Add async firmware cache clearing for multi-bond support #123

Workflow file

Add async firmware cache clearing for multi-bond support #123

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Workflow file for this run