fix: four real firmware defects found in adversarial review

rd03e.c: RD03E_FRAME_LEN was 5 but the frame's own documented layout
(header + gesture + distance_lo + distance_hi + footer[2]) is 6 bytes.
The footer check read buf[i+3], colliding with the distance high byte at
that same index — so every frame that validated at all was forced to have
distance_cm = lo | 0x5500 (~218m) regardless of what the sensor reported.
Distance readings were garbage 100% of the time, not intermittently.

mems_mic.c: i2s_del_channel() was missing on 2 of 3 init failure paths,
leaking the channel handle.

bmp280.c: the I2C bus/device handles leaked on 4 of 5 init failure paths;
added a fail label that releases both.

app_main.c: sensors now init before Wi-Fi bring-up, matching the rationale
sensor_driver.h already documents (a hanging sensor bus must not be able to
block network bring-up).

rtlsdr_experimental.c: rtlsdr_exp_stop() waited 500ms before
usb_host_uninstall(), but the daemon task blocks up to 1000ms inside
usb_host_lib_handle_events() before re-checking its running flag — the
delay must exceed that or teardown races a live daemon task.

Co-Authored-By: Claude Opus 5 <noreply@anthropic.com>

firmware/esp32p4-sensor-node/components/rtlsdr_experimental/rtlsdr_experimental.c

@@ -897,10 +897,14 @@ esp_err_t rtlsdr_exp_stop(rtlsdr_exp_handle_t h)
 
     h->running = false;
     /* Tasks self-delete once they observe h->running == false; give them a
-     * moment. A production version should use task-completion notification
+     * moment. The daemon task blocks up to 1000ms per iteration inside
-     * instead of a fixed delay — left as a TODO, not hardware-dependent but
+     * usb_host_lib_handle_events() before it re-checks h->running, so this
-     * still unverified/untuned. */
+     * delay must exceed that or usb_host_uninstall() below can race a still
-    vTaskDelay(pdMS_TO_TICKS(500));
+     * -running daemon task still holding the USB host lib open. A production
+     * version should use task-completion notification instead of a fixed
+     * delay — left as a TODO, not hardware-dependent but still
+     * unverified/untuned. */
+    vTaskDelay(pdMS_TO_TICKS(1200));
 
     usb_host_uninstall(); /* see rtlsdr_exp_start() note re: sole USB client assumption */
     return ESP_OK;

firmware/esp32p4-sensor-node/main/app_main.c

@@ -8,13 +8,15 @@
 // correctly" is where the verification stops. See README.md's "What's
 // verified vs. not" section before treating any of this as field-tested.
 //
-// Boot sequence: bring up Wi-Fi station mode (device_config.h credentials),
+// Boot sequence: initialize every registered sensor driver first (so a
-// wait (briefly, non-fatally) for an initial connection, initialize every
+// slow/hanging sensor bus can't block network bring-up -- see
-// registered sensor driver, then hand off to the telemetry task, which
+// sensor_driver.h), then bring up Wi-Fi station mode (device_config.h
-// periodically samples the sensor registry and POSTs the results to the
+// credentials), wait (briefly, non-fatally) for an initial connection, and
-// backend. Wi-Fi reconnection and per-cycle "are we online" checks happen
+// hand off to the telemetry task, which periodically samples the sensor
-// independently after this, so a boot-time Wi-Fi hiccup doesn't wedge the
+// registry and POSTs the results to the backend. Wi-Fi reconnection and
-// device -- it just starts reporting once the connection comes up.
+// per-cycle "are we online" checks happen independently after this, so a
+// boot-time Wi-Fi hiccup doesn't wedge the device -- it just starts
+// reporting once the connection comes up.
 
 #include "wifi_manager.h"
 #include "sensor_registry.h"
@@ -34,6 +36,8 @@ static const char *TAG = "app_main";
 void app_main(void) {
     ESP_LOGI(TAG, "Quantumancy sensor node starting");
 
+    sensor_registry_init_all();
+
     ESP_ERROR_CHECK(wifi_manager_start());
 
     esp_err_t err = wifi_manager_wait_connected(pdMS_TO_TICKS(BOOT_WIFI_WAIT_MS));
@@ -44,7 +48,6 @@ void app_main(void) {
                        "wifi_manager will keep retrying in the background", BOOT_WIFI_WAIT_MS);
     }
 
-    sensor_registry_init_all();
     telemetry_client_start_task();
 
     ESP_LOGI(TAG, "startup complete, telemetry task running");

firmware/esp32p4-sensor-node/main/bmp280.c

@@ -122,6 +122,8 @@ esp_err_t bmp280_init(void) {
     err = i2c_master_bus_add_device(s_bus, &dev_cfg, &s_dev);
     if (err != ESP_OK) {
         ESP_LOGE(TAG, "i2c_master_bus_add_device failed: %s", esp_err_to_name(err));
+        i2c_del_master_bus(s_bus);
+        s_bus = NULL;
         return err;
     }
 
@@ -129,7 +131,7 @@ esp_err_t bmp280_init(void) {
     err = read_regs(REG_CHIP_ID, &chip_id, 1);
     if (err != ESP_OK) {
         ESP_LOGE(TAG, "chip id read failed: %s", esp_err_to_name(err));
-        return err;
+        goto fail;
     }
     if (chip_id != CHIP_ID_EXPECTED) {
         ESP_LOGW(TAG, "unexpected chip id 0x%02x (want 0x%02x) -- check wiring/address", chip_id, CHIP_ID_EXPECTED);
@@ -139,18 +141,25 @@ esp_err_t bmp280_init(void) {
     }
 
     err = write_reg(REG_RESET, RESET_MAGIC);
-    if (err != ESP_OK) return err;
+    if (err != ESP_OK) goto fail;
     vTaskDelay(pdMS_TO_TICKS(10)); // datasheet: allow >= 2ms after reset
 
     err = read_calibration();
     if (err != ESP_OK) {
         ESP_LOGE(TAG, "calibration read failed: %s", esp_err_to_name(err));
-        return err;
+        goto fail;
     }
 
     s_ready = true;
     ESP_LOGI(TAG, "BMP280 init ok (chip id 0x%02x)", chip_id);
     return ESP_OK;
+
+fail:
+    i2c_master_bus_rm_device(s_dev);
+    s_dev = NULL;
+    i2c_del_master_bus(s_bus);
+    s_bus = NULL;
+    return err;
 }
 
 // Bosch datasheet 3.11.3 double-precision reference compensation formulas,

firmware/esp32p4-sensor-node/main/mems_mic.c

@@ -73,6 +73,8 @@ esp_err_t mems_mic_init(void) {
     err = i2s_channel_init_std_mode(s_rx_chan, &std_cfg);
     if (err != ESP_OK) {
         ESP_LOGE(TAG, "i2s_channel_init_std_mode failed: %s", esp_err_to_name(err));
+        i2s_del_channel(s_rx_chan);
+        s_rx_chan = NULL;
         free(s_sample_buf);
         s_sample_buf = NULL;
         return err;
@@ -81,6 +83,8 @@ esp_err_t mems_mic_init(void) {
     err = i2s_channel_enable(s_rx_chan);
     if (err != ESP_OK) {
         ESP_LOGE(TAG, "i2s_channel_enable failed: %s", esp_err_to_name(err));
+        i2s_del_channel(s_rx_chan);
+        s_rx_chan = NULL;
         free(s_sample_buf);
         s_sample_buf = NULL;
         return err;

firmware/esp32p4-sensor-node/main/rd03e.c

@@ -12,7 +12,7 @@
 // "simple report" output frames, which need no configuration to start
 // streaming after power-up.
 //
-// Simple report frame, as reconstructed (5 bytes total):
+// Simple report frame, as reconstructed (6 bytes total):
 //   [0]     0xAA               frame header
 //   [1]     gesture code       raw value, meaning not confirmed against an
 //                               official datasheet — reported as-is in
@@ -36,7 +36,7 @@ static const char *TAG = "rd03e";
 
 #define RD03E_RX_BUF_SIZE   512
 #define RD03E_SCRATCH_SIZE  256
-#define RD03E_FRAME_LEN     5
+#define RD03E_FRAME_LEN     6
 
 static const uint8_t FRAME_HEADER = 0xAA;
 static const uint8_t FRAME_FOOTER[2] = { 0x55, 0x55 };
@@ -116,7 +116,7 @@ esp_err_t rd03e_read(sensor_reading_t *out, size_t max_out, size_t *out_count) {
         if (buf[i] != FRAME_HEADER) {
             continue;
         }
-        if (memcmp(&buf[i + 3], FRAME_FOOTER, 2) != 0) {
+        if (memcmp(&buf[i + 4], FRAME_FOOTER, 2) != 0) {
             continue; // not a real header byte, or a corrupted frame
         }
         latest.gesture = buf[i + 1];