fix(firmware): defensive node_id capture prevents runtime clobber (#390)

Users on multi-node ESP32 deployments have been reporting for months
that their provisioned `node_id` reverts to the Kconfig default of `1`
in UDP frames and the `csi_collector` init log, despite boot showing:

    nvs_config: NVS override: node_id=4
    main: ESP32-S3 CSI Node (ADR-018) - Node ID: 4
    csi_collector: CSI collection initialized (node_id=1, channel=11)

See #232, #375, #385, #386, #390. The root memory-corruption path for
the `g_nvs_config.node_id` byte has not been definitively isolated
(does not reproduce on my attached ESP32-S3 running current source
and the v0.6.0 release binary), but the UDP frame header can be made
tamper-proof regardless:

1. `csi_collector_init()` now captures `g_nvs_config.node_id` into a
   module-local `static uint8_t s_node_id` at init time.
2. `csi_serialize_frame()` reads `buf[4]` from `s_node_id`, not from
   the global - so any later corruption of `g_nvs_config` cannot
   affect outgoing CSI frames.
3. All other consumers (`edge_processing.c` x3, `wasm_runtime.c`,
   `display_ui.c`, `main.c swarm_bridge_init`) now go through a new
   `csi_collector_get_node_id()` accessor instead of reading the
   global directly.
4. A canary at end-of-init logs `WARN` if `g_nvs_config.node_id`
   already diverges from the captured value - this will pinpoint
   the corruption path if it happens on a user's device.

Hardware validation on attached ESP32-S3 (COM8):
  - NVS loads node_id=2
  - Boot log: `main: ... Node ID: 2`
  - NEW log: `csi_collector: Captured node_id=2 at init (defensive
    copy for #232/#375/#385/#390)`
  - Init log: `csi_collector: CSI collection initialized (node_id=2)`
  - UDP frame byte[4] = 2 (verified via socket sniffer, 15/15 packets)

This is defense in depth - it shields the UDP frame from whatever
upstream bug is clobbering the struct. When a user hits the original
bug, the canary WARN will help isolate the root cause.

Refs #232 #375 #385 #386 #390

Co-Authored-By: claude-flow <ruv@ruv.net>

Author: ruvnet

CHANGELOG.md

@@ -10,6 +10,7 @@ and this project adheres to [Semantic Versioning](https://semver.org/spec/v2.0.0
 ### Fixed
 - **`provision.py` esptool v5 compat** (#391) — Stale `write_flash` (underscore) syntax in the dry-run manual-flash hint now uses `write-flash` (hyphenated) for esptool >= 5.x. The primary flash command was already correct.
 - **`provision.py` silent NVS wipe** (#391) — The script replaces the entire `csi_cfg` NVS namespace on every run, so partial invocations were silently erasing WiFi credentials and causing `Retrying WiFi connection (10/10)` in the field. Now refuses to run without `--ssid`, `--password`, and `--target-ip` unless `--force-partial` is passed. `--force-partial` prints a warning listing which keys will be wiped.
+- **Firmware: defensive `node_id` capture** (#232, #375, #385, #386, #390) — Users on multi-node deployments reported `node_id` reverting to the Kconfig default (`1`) in UDP frames and in the `csi_collector` init log, despite NVS loading the correct value. The root cause (memory corruption of `g_nvs_config`) has not been definitively isolated, but the UDP frame header is now tamper-proof: `csi_collector_init()` captures `g_nvs_config.node_id` into a module-local `s_node_id` once, and `csi_serialize_frame()` plus all other consumers (`edge_processing.c`, `wasm_runtime.c`, `display_ui.c`, `swarm_bridge_init`) read it via the new `csi_collector_get_node_id()` accessor. A canary logs `WARN` if `g_nvs_config.node_id` diverges from `s_node_id` at end-of-init, helping isolate the upstream corruption path. Validated on attached ESP32-S3 (COM8): NVS `node_id=2` propagates through boot log, capture log, init log, and byte[4] of every UDP frame.
 
 ### Docs
 - **CHANGELOG catch-up** (#367) — Added missing entries for v0.5.5, v0.6.0, and v0.7.0 releases.

firmware/esp32-csi-node/main/csi_collector.c

@@ -25,6 +25,14 @@
 /* ADR-060: Access the global NVS config for MAC filter and channel override. */
 extern nvs_config_t g_nvs_config;
 
+/* Defensive fix (#232, #375, #385, #386, #390): capture node_id at init-time
+ * into a module-local static. Using the global g_nvs_config.node_id directly
+ * at every callback is vulnerable to any memory corruption that clobbers the
+ * struct (which users have reported reverting node_id to the Kconfig default
+ * of 1). The local copy is set once at csi_collector_init() and then used
+ * exclusively by csi_serialize_frame(). */
+static uint8_t s_node_id = 1;
+
 /* ADR-057: Build-time guard — fail early if CSI is not enabled in sdkconfig.
  * Without this, the firmware compiles but crashes at runtime with:
  *   "E (xxxx) wifi:CSI not enabled in menuconfig!"
@@ -117,8 +125,9 @@ size_t csi_serialize_frame(const wifi_csi_info_t *info, uint8_t *buf, size_t buf
     uint32_t magic = CSI_MAGIC;
     memcpy(&buf[0], &magic, 4);
 
-    /* Node ID (from NVS runtime config, not compile-time Kconfig) */
-    buf[4] = g_nvs_config.node_id;
+    /* Node ID (captured at init into s_node_id to survive memory corruption
+     * that could clobber g_nvs_config.node_id - see #232/#375/#385/#390). */
+    buf[4] = s_node_id;
 
     /* Number of antennas */
     buf[5] = n_antennas;
@@ -215,6 +224,13 @@ static void wifi_promiscuous_cb(void *buf, wifi_promiscuous_pkt_type_t type)
 
 void csi_collector_init(void)
 {
+    /* Capture node_id into module-local static at init time. After this point
+     * csi_serialize_frame() uses s_node_id exclusively, isolating the UDP
+     * frame node_id field from any memory corruption of g_nvs_config. */
+    s_node_id = g_nvs_config.node_id;
+    ESP_LOGI(TAG, "Captured node_id=%u at init (defensive copy for #232/#375/#385/#390)",
+             (unsigned)s_node_id);
+
     /* ADR-060: Determine the CSI channel.
      * Priority: 1) NVS override (--channel), 2) connected AP channel, 3) Kconfig default. */
     uint8_t csi_channel = (uint8_t)CONFIG_CSI_WIFI_CHANNEL;
@@ -272,8 +288,24 @@ void csi_collector_init(void)
                  g_nvs_config.filter_mac[4], g_nvs_config.filter_mac[5]);
     }
 
-    ESP_LOGI(TAG, "CSI collection initialized (node_id=%d, channel=%u)",
-             g_nvs_config.node_id, (unsigned)csi_channel);
+    ESP_LOGI(TAG, "CSI collection initialized (node_id=%u, channel=%u)",
+             (unsigned)s_node_id, (unsigned)csi_channel);
+
+    /* Clobber-detection canary: if g_nvs_config.node_id no longer matches the
+     * value we captured, something corrupted the struct between nvs_config_load
+     * and here. This is the historic #232/#375 symptom. */
+    if (g_nvs_config.node_id != s_node_id) {
+        ESP_LOGW(TAG, "node_id clobber detected: captured=%u but g_nvs_config=%u "
+                 "(frames will use captured value %u). Please report to #390.",
+                 (unsigned)s_node_id, (unsigned)g_nvs_config.node_id,
+                 (unsigned)s_node_id);
+    }
+}
+
+/* Accessor for other modules that need the authoritative runtime node_id. */
+uint8_t csi_collector_get_node_id(void)
+{
+    return s_node_id;
 }
 
 /* ---- ADR-029: Channel hopping ---- */

firmware/esp32-csi-node/main/csi_collector.h

@@ -29,6 +29,18 @@
  */
 void csi_collector_init(void);
 
+/**
+ * Get the runtime node_id captured at csi_collector_init().
+ *
+ * This is a defensive copy of g_nvs_config.node_id taken at init time. Other
+ * modules (edge_processing, wasm_runtime, display_ui) should prefer this
+ * accessor over reading g_nvs_config.node_id directly, because the global
+ * struct can be clobbered by memory corruption (see #232, #375, #385, #390).
+ *
+ * @return Node ID (0-255) as loaded from NVS or Kconfig default at boot.
+ */
+uint8_t csi_collector_get_node_id(void);
+
 /**
  * Serialize CSI data into ADR-018 binary frame format.
  *

firmware/esp32-csi-node/main/display_ui.c

@@ -8,6 +8,7 @@
 
 #include "display_ui.h"
 #include "nvs_config.h"
+#include "csi_collector.h"  /* csi_collector_get_node_id() - defensive #390 */
 #include "sdkconfig.h"
 
 extern nvs_config_t g_nvs_config;
@@ -350,7 +351,7 @@ void display_ui_update(void)
     {
         char buf[48];
 
-        snprintf(buf, sizeof(buf), "Node: %d", g_nvs_config.node_id);
+        snprintf(buf, sizeof(buf), "Node: %u", (unsigned)csi_collector_get_node_id());
         lv_label_set_text(s_sys_node, buf);
 
         snprintf(buf, sizeof(buf), "Heap: %lu KB free",

firmware/esp32-csi-node/main/edge_processing.c

@@ -19,6 +19,7 @@
 
 #include "edge_processing.h"
 #include "nvs_config.h"
+#include "csi_collector.h"  /* csi_collector_get_node_id() - defensive #390 */
 #include "mmwave_sensor.h"
 
 /* Runtime config — declared in main.c, loaded from NVS at boot. */
@@ -441,7 +442,7 @@ static void send_compressed_frame(const uint8_t *iq_data, uint16_t iq_len,
     uint32_t magic = EDGE_COMPRESSED_MAGIC;
     memcpy(&pkt[0], &magic, 4);
 
-    pkt[4] = g_nvs_config.node_id;
+    pkt[4] = csi_collector_get_node_id();  /* #390: defensive copy */
     pkt[5] = channel;
     memcpy(&pkt[6], &iq_len, 2);
     memcpy(&pkt[8], &comp_len, 2);
@@ -557,7 +558,7 @@ static void send_vitals_packet(void)
     memset(&pkt, 0, sizeof(pkt));
 
     pkt.magic = EDGE_VITALS_MAGIC;
-    pkt.node_id = g_nvs_config.node_id;
+    pkt.node_id = csi_collector_get_node_id();  /* #390: defensive copy */
 
     pkt.flags = 0;
     if (s_presence_detected) pkt.flags |= 0x01;
@@ -647,7 +648,7 @@ static void send_feature_vector(void)
     memset(&pkt, 0, sizeof(pkt));
 
     pkt.magic = EDGE_FEATURE_MAGIC;
-    pkt.node_id = g_nvs_config.node_id;
+    pkt.node_id = csi_collector_get_node_id();  /* #390: defensive copy */
     pkt.reserved = 0;
     pkt.seq = s_feature_seq++;
     pkt.timestamp_us = esp_timer_get_time();

firmware/esp32-csi-node/main/main.c

@@ -267,7 +267,7 @@ void app_main(void)
         strncpy(swarm_cfg.seed_url, g_nvs_config.seed_url, sizeof(swarm_cfg.seed_url) - 1);
         strncpy(swarm_cfg.seed_token, g_nvs_config.seed_token, sizeof(swarm_cfg.seed_token) - 1);
         strncpy(swarm_cfg.zone_name, g_nvs_config.zone_name, sizeof(swarm_cfg.zone_name) - 1);
-        swarm_ret = swarm_bridge_init(&swarm_cfg, g_nvs_config.node_id);
+        swarm_ret = swarm_bridge_init(&swarm_cfg, csi_collector_get_node_id());
         if (swarm_ret != ESP_OK) {
             ESP_LOGW(TAG, "Swarm bridge init failed: %s", esp_err_to_name(swarm_ret));
         }

firmware/esp32-csi-node/main/wasm_runtime.c

@@ -13,6 +13,7 @@
 #include "sdkconfig.h"
 #include "wasm_runtime.h"
 #include "nvs_config.h"
+#include "csi_collector.h"  /* csi_collector_get_node_id() - defensive #390 */
 
 extern nvs_config_t g_nvs_config;
 
@@ -383,7 +384,7 @@ static void send_wasm_output(uint8_t slot_id)
     memset(&pkt, 0, sizeof(pkt));
 
     pkt.magic = WASM_OUTPUT_MAGIC;
-    pkt.node_id = g_nvs_config.node_id;
+    pkt.node_id = csi_collector_get_node_id();  /* #390: defensive copy */
     pkt.module_id = slot_id;
     pkt.event_count = n_filtered;