fix(control-plane): optimize task monitoring and worker stacks

components/control_plane/src/multimodal/control_plane_multimodal_runtime.c

@@ -36,10 +36,14 @@
 #define CONFIG_MULTIMODAL_AUDIO_PREWARM_OPUS_BEFORE_WS 1
 #endif
 
+#ifndef CONFIG_TQ_MULTIMODAL_WATCHDOG_TASK_STACK_BYTES
+#define CONFIG_TQ_MULTIMODAL_WATCHDOG_TASK_STACK_BYTES (6U * 1024U)
+#endif
+
 #define CONTROL_PLANE_DOWNSTREAM_PLAYBACK_GUARD_MS 220
 #define CONTROL_PLANE_DOWNSTREAM_STALL_STOP_GRACE_MS 2000
 #define CONTROL_PLANE_IDLE_TRANSPORT_SHUTDOWN_MS 30000
-#define CONTROL_PLANE_WATCHDOG_TASK_STACK_SIZE 8192
+#define CONTROL_PLANE_WATCHDOG_TASK_STACK_SIZE CONFIG_TQ_MULTIMODAL_WATCHDOG_TASK_STACK_BYTES
 #define CONTROL_PLANE_SERVER_SUCCESS_PROMPT_FILE "/littlefs/audio_prompts/server_connect_success.opus"
 #define CONTROL_PLANE_CLIENT_LIFECYCLE_WAIT_MS 30000U
 #define CONTROL_PLANE_SERVER_SUCCESS_PROMPT_RETRY_MS 1000U

components/control_plane/src/runtime/control_plane_factory_cli.c

@@ -30,7 +30,11 @@
 #define FACTORY_CLI_SERIAL_MAX_LEN     64
 #define FACTORY_CLI_JSON_MAX_LEN       640
 #define FACTORY_CLI_READ_TIMEOUT_MS    100
-#define FACTORY_CLI_WORKER_STACK_BYTES (12U * 1024U)
+#ifndef CONFIG_TQ_FACTORY_CLI_TASK_STACK_BYTES
+#define CONFIG_TQ_FACTORY_CLI_TASK_STACK_BYTES (10U * 1024U)
+#endif
+
+#define FACTORY_CLI_WORKER_STACK_BYTES CONFIG_TQ_FACTORY_CLI_TASK_STACK_BYTES
 #define FACTORY_CLI_WORKER_PRIORITY    4
 #define FACTORY_CLI_STOP_WAIT_STEPS    100
 #define FACTORY_CLI_STOP_WAIT_STEP_MS  20

components/control_plane/src/runtime/control_plane_runtime_workers.c

@@ -20,10 +20,16 @@
 #include "freertos/task.h"
 #include "sdkconfig.h"
 
+#ifndef CONFIG_TQ_LCD_RENDER_TASK_STACK_BYTES
+#define CONFIG_TQ_LCD_RENDER_TASK_STACK_BYTES (10U * 1024U)
+#endif
+
 #define CONTROL_PLANE_MODEL_CMD_TASK_STACK_SIZE    (1024 * 4)
-#define CONTROL_PLANE_LCD_RENDER_LOOP_TASK_STACK_SIZE (1024 * 12)
+#define CONTROL_PLANE_LCD_RENDER_LOOP_TASK_STACK_SIZE CONFIG_TQ_LCD_RENDER_TASK_STACK_BYTES
 #define CONTROL_PLANE_WIFI_STATE_TASK_STACK_SIZE   (1024 * 10)
 #define CONTROL_PLANE_TASK_MONITOR_TASK_STACK_SIZE (1024 * 4)
+#define CONTROL_PLANE_TASK_MONITOR_STACK_WARN_BYTES 1024U
+#define CONTROL_PLANE_TASK_MONITOR_FULL_REPORT_PERIOD 5U
 #define CONTROL_PLANE_REMOTE_LOG_STOP_WAIT_MS      1500
 #define CONTROL_PLANE_MODEL_CMD_QUEUE_LEN          4
 #define CONTROL_PLANE_MODEL_CMD_RECV_TIMEOUT_MS    200
@@ -1404,7 +1410,39 @@ static const char *control_plane_task_core_name(BaseType_t core_id,
     return buffer;
 }
 
-static void control_plane_log_task_table(void)
+static void control_plane_log_task_status(const TaskStatus_t *task, bool warn)
+{
+    if (task == NULL) {
+        return;
+    }
+
+    char core_buf[12] = {0};
+    const char *name = task->pcTaskName != NULL ? task->pcTaskName : "?";
+    const char *state = control_plane_task_state_name(task->eCurrentState);
+    const char *core = control_plane_task_core_name(
+            xTaskGetCoreID(task->xHandle), core_buf, sizeof(core_buf));
+    if (warn) {
+        ESP_LOGW(TAG,
+                 "Task stack headroom low: name=%s state=%s priority=%u headroom=%uB core=%s",
+                 name,
+                 state,
+                 (unsigned int)task->uxCurrentPriority,
+                 (unsigned int)task->usStackHighWaterMark,
+                 core);
+        return;
+    }
+
+    ESP_LOGI(TAG,
+             "%-16s %-5s %-4u %-10u %-4s %-10lu",
+             name,
+             state,
+             (unsigned int)task->uxCurrentPriority,
+             (unsigned int)task->usStackHighWaterMark,
+             core,
+             (unsigned long)task->ulRunTimeCounter);
+}
+
+static void control_plane_log_task_table(bool full_report)
 {
 #if !configUSE_TRACE_FACILITY
     ESP_LOGW(TAG, "Task monitor requires CONFIG_FREERTOS_USE_TRACE_FACILITY");
@@ -1422,42 +1460,61 @@ static void control_plane_log_task_table(void)
         return;
     }
 
-    TaskStatus_t *tasks = (TaskStatus_t *)calloc(capture_count, sizeof(TaskStatus_t));
+    TaskStatus_t *tasks = (TaskStatus_t *)heap_caps_calloc(
+            capture_count,
+            sizeof(TaskStatus_t),
+            MALLOC_CAP_SPIRAM | MALLOC_CAP_8BIT);
     if (tasks == NULL) {
-        ESP_LOGW(TAG, "Task monitor allocation failed: entries=%u",
+        ESP_LOGW(TAG, "Task monitor PSRAM snapshot allocation failed: entries=%u",
                  (unsigned int)capture_count);
         return;
     }
 
     uint32_t total_runtime = 0;
     UBaseType_t captured = uxTaskGetSystemState(tasks, capture_count, &total_runtime);
+    const TaskStatus_t *lowest = NULL;
+    UBaseType_t low_count = 0U;
+    for (UBaseType_t i = 0; i < captured; ++i) {
+        if (lowest == NULL ||
+            tasks[i].usStackHighWaterMark < lowest->usStackHighWaterMark) {
+            lowest = &tasks[i];
+        }
+        if (tasks[i].usStackHighWaterMark <
+            CONTROL_PLANE_TASK_MONITOR_STACK_WARN_BYTES) {
+            low_count++;
+        }
+    }
 
     ESP_LOGI(TAG,
-             "Task monitor: total=%u captured=%u runtime=%lu",
+             "Task monitor summary: total=%u captured=%u runtime=%lu lowest=%s/%uB low=%u snapshot=PSRAM full=%d",
              (unsigned int)task_count,
              (unsigned int)captured,
-             (unsigned long)total_runtime);
+             (unsigned long)total_runtime,
-    ESP_LOGI(TAG, "%-16s %-5s %-4s %-7s %-4s %-10s",
+             lowest != NULL && lowest->pcTaskName != NULL ? lowest->pcTaskName : "?",
+             lowest != NULL ? (unsigned int)lowest->usStackHighWaterMark : 0U,
+             (unsigned int)low_count,
+             full_report ? 1 : 0);
+    if (!full_report) {
+        heap_caps_free(tasks);
+        return;
+    }
+
+    ESP_LOGI(TAG, "%-16s %-5s %-4s %-10s %-4s %-10s",
              "name",
              "state",
              "prio",
-             "stack",
+             "headroom",
              "core",
              "runtime");
 
     for (UBaseType_t i = 0; i < captured; ++i) {
-        char core_buf[12] = {0};
+        control_plane_log_task_status(
-        ESP_LOGI(TAG,
+                &tasks[i],
-                 "%-16s %-5s %-4u %-7u %-4s %-10lu",
+                tasks[i].usStackHighWaterMark <
-                 tasks[i].pcTaskName != NULL ? tasks[i].pcTaskName : "?",
+                        CONTROL_PLANE_TASK_MONITOR_STACK_WARN_BYTES);
-                 control_plane_task_state_name(tasks[i].eCurrentState),
-                 (unsigned int)tasks[i].uxCurrentPriority,
-                 (unsigned int)tasks[i].usStackHighWaterMark,
-                 control_plane_task_core_name(xTaskGetCoreID(tasks[i].xHandle), core_buf, sizeof(core_buf)),
-                 (unsigned long)tasks[i].ulRunTimeCounter);
     }
 
-    free(tasks);
+    heap_caps_free(tasks);
 #endif
 }
 
@@ -1466,9 +1523,11 @@ static void control_plane_task_monitor_task(void *arg)
     (void)arg;
 
     ESP_LOGI(TAG,
-             "Task monitor started interval=%dms max_tasks=%d",
+             "Task monitor started interval=%dms max_tasks=%d stack=PSRAM-preferred snapshot=PSRAM full_period=%u warn=%uB",
              CONFIG_TQ_TASK_MONITOR_INTERVAL_MS,
-             CONFIG_TQ_TASK_MONITOR_MAX_TASKS);
+             CONFIG_TQ_TASK_MONITOR_MAX_TASKS,
+             (unsigned)CONTROL_PLANE_TASK_MONITOR_FULL_REPORT_PERIOD,
+             (unsigned)CONTROL_PLANE_TASK_MONITOR_STACK_WARN_BYTES);
 
     TickType_t interval_ticks = pdMS_TO_TICKS(CONFIG_TQ_TASK_MONITOR_INTERVAL_MS);
     if (interval_ticks == 0) {
@@ -1478,8 +1537,12 @@ static void control_plane_task_monitor_task(void *arg)
         interval_ticks = 1;
     }
 
+    uint32_t report_count = 0U;
     while (!control_plane_runtime_stop_requested()) {
-        control_plane_log_task_table();
+        bool full_report =
+                (report_count % CONTROL_PLANE_TASK_MONITOR_FULL_REPORT_PERIOD) == 0U;
+        control_plane_log_task_table(full_report);
+        report_count++;
         vTaskDelay(interval_ticks);
     }
 
@@ -2549,12 +2612,13 @@ esp_err_t control_plane_start_runtime_workers(void)
 
 #if CONFIG_TQ_TASK_MONITOR_ENABLE
     if (control_plane_get_task_handle(&s_task_monitor_task) == NULL) {
-        esp_err_t task_err = control_plane_create_task(control_plane_task_monitor_task,
+        esp_err_t task_err = control_plane_create_task_psram_first(
-                                                       "cp_task_monitor",
+                control_plane_task_monitor_task,
-                                                       CONTROL_PLANE_TASK_MONITOR_TASK_STACK_SIZE,
+                "cp_task_monitor",
-                                                       3,
+                CONTROL_PLANE_TASK_MONITOR_TASK_STACK_SIZE,
-                                                       CONTROL_PLANE_LOCAL_TASK_CORE,
+                3,
-                                                       &s_task_monitor_task);
+                CONTROL_PLANE_LOCAL_TASK_CORE,
+                &s_task_monitor_task);
         if (task_err != ESP_OK) {
             control_plane_stop_runtime_workers();
             return task_err;
@@ -2703,7 +2767,7 @@ void control_plane_stop_runtime_workers(void)
     }
 #if CONFIG_TQ_TASK_MONITOR_ENABLE
     if (!control_plane_wait_task_exit(&s_task_monitor_task, CONTROL_PLANE_TASK_STOP_WAIT_MS)) {
-        control_plane_force_delete_task(&s_task_monitor_task, "cp_task_monitor");
+        control_plane_force_delete_task_with_caps(&s_task_monitor_task, "cp_task_monitor");
     }
 #endif
 #if CONFIG_FORTUNE_ENABLE

components/control_plane/src/runtime/control_plane_system_events.c

@@ -27,7 +27,7 @@
 #endif
 
 #ifndef CONFIG_TQ_SYSTEM_EVENT_TASK_STACK
-#define CONFIG_TQ_SYSTEM_EVENT_TASK_STACK 4096
+#define CONFIG_TQ_SYSTEM_EVENT_TASK_STACK 6144
 #endif
 
 #if !defined(CONFIG_TQ_PTT_MODE_HOLD_TO_TALK) && !defined(CONFIG_TQ_PTT_MODE_CLICK_TO_TALK)

main/Kconfig.projbuild

@@ -211,15 +211,18 @@ menu "Example Configuration"
             bool "Enable periodic FreeRTOS task monitor log"
             default y
             help
-                Periodically print a compact FreeRTOS task table to the log.
+                Run a low-impact task monitor with a PSRAM-preferred worker
+                stack and PSRAM-only snapshots. Periodic summaries report the
+                lowest stack headroom; a full task table is emitted less often.
 
         config TQ_TASK_MONITOR_INTERVAL_MS
             int "Task monitor log interval (ms)"
-            default 10000
+            default 30000
             range 1000 600000
             depends on TQ_TASK_MONITOR_ENABLE
             help
-                Interval for periodic task table logging.
+                Interval for task summaries. The complete table is emitted on
+                the first sample and every five samples after that.
 
         config TQ_TASK_MONITOR_MAX_TASKS
             int "Task monitor max task entries"
@@ -317,7 +320,7 @@ menu "Example Configuration"
 
         config TQ_SYSTEM_EVENT_TASK_STACK
             int "System event task stack size"
-            default 4096
+            default 6144
             range 2048 8192
             depends on TQ_SYSTEM_EVENT_ENABLE
             help
@@ -680,6 +683,14 @@ menu "Example Configuration"
                 Disable when the connected display hardware does not match this
                 firmware's LCD driver.
 
+        config TQ_LCD_RENDER_TASK_STACK_BYTES
+            int "LCD render task stack (bytes)"
+            default 10240
+            range 8192 16384
+            depends on TQ_SCREEN_ENABLE
+            help
+                Stack size in bytes for the control-plane LCD render worker.
+
         config TQ_SCREEN_COLOR_ORDER_BGR
             bool "Use BGR color order"
             default n
@@ -1154,6 +1165,14 @@ menu "Example Configuration"
             help
                 Master switch for multimodal WebSocket interaction features.
 
+        config TQ_MULTIMODAL_WATCHDOG_TASK_STACK_BYTES
+            int "Multimodal watchdog task stack (bytes)"
+            default 6144
+            range 4096 12288
+            depends on ENABLE_MULTIMODAL_INTERACTION
+            help
+                Stack size in bytes for the multimodal session watchdog task.
+
         config MULTIMODAL_USE_STATIC_CREDENTIALS
             bool "Use static WebSocket credentials (skip token request)"
             default n
@@ -1230,6 +1249,14 @@ menu "Example Configuration"
                 device identity provisioning, public-key retrieval, and
                 on-device challenge signing.
 
+        config TQ_FACTORY_CLI_TASK_STACK_BYTES
+            int "Factory CLI task stack (bytes)"
+            default 10240
+            range 8192 16384
+            depends on TQ_FACTORY_CLI_ENABLE
+            help
+                Stack size in bytes for the serial factory provisioning worker.
+
         config AUTH_REGISTER_BASE_URL
             string "Auth V2 registration base URL"
             depends on AUTH_V2_ENABLE

sdkconfig.defaults

@@ -37,7 +37,8 @@ CONFIG_TQ_BOOT_SOUND_TIMEOUT_MS=3000
 CONFIG_TQ_BOOT_SOUND_FILE="boot.opus"
 CONFIG_TQ_NETWORK_TASK_CORE=0
 CONFIG_TQ_LOCAL_TASK_CORE=1
-CONFIG_TQ_TASK_MONITOR_INTERVAL_MS=10000
+CONFIG_TQ_LCD_RENDER_TASK_STACK_BYTES=10240
+CONFIG_TQ_TASK_MONITOR_INTERVAL_MS=30000
 CONFIG_TQ_TASK_MONITOR_MAX_TASKS=64
 CONFIG_TQ_MEMORY_MONITOR_ENABLE=y
 CONFIG_TQ_MEMORY_MONITOR_SAMPLE_INTERVAL_MS=1000
@@ -49,7 +50,7 @@ CONFIG_TQ_MULTIMODAL_DIAGNOSTICS_ENABLE=y
 CONFIG_TQ_NETWORK_AUTO_REASSOCIATION_ENABLE=y
 CONFIG_TQ_SYSTEM_EVENT_ENABLE=y
 CONFIG_TQ_SYSTEM_EVENT_QUEUE_LEN=32
-CONFIG_TQ_SYSTEM_EVENT_TASK_STACK=4096
+CONFIG_TQ_SYSTEM_EVENT_TASK_STACK=6144
 CONFIG_TQ_LIGHT_STANDBY_ENABLE=y
 CONFIG_TQ_LIGHT_STANDBY_IDLE_TIMEOUT_MS=300000
 CONFIG_TQ_LIGHT_STANDBY_DIM_BACKLIGHT=y
@@ -190,10 +191,12 @@ CONFIG_FORTUNE_USER_CONFIG_HTTP_PORT=80
 CONFIG_FORTUNE_USER_CONFIG_MDNS_HOSTNAME="tq-cat"
 # CONFIG_FORTUNE_USE_DEVICE_JWT is not set
 CONFIG_ENABLE_MULTIMODAL_INTERACTION=y
+CONFIG_TQ_MULTIMODAL_WATCHDOG_TASK_STACK_BYTES=6144
 # CONFIG_MULTIMODAL_USE_STATIC_CREDENTIALS is not set
 # CONFIG_MULTIMODAL_AUTH_BYPASS_TOKEN_SERVICE is not set
 CONFIG_AUTH_V2_ENABLE=y
 CONFIG_TQ_FACTORY_CLI_ENABLE=y
+CONFIG_TQ_FACTORY_CLI_TASK_STACK_BYTES=10240
 CONFIG_MULTIMODAL_UPSTREAM_MODE="push2talk"
 CONFIG_MULTIMODAL_PTT_BUTTON_GPIO=13
 CONFIG_MULTIMODAL_PTT_BUTTON_ACTIVE_LEVEL=0