[BUG] [ZEPHYR] sof-logger dead: Invalid filename length 1650680879 or ldc file does not match firmware #5352
Description
Rarely, the sof-logger dies like this at the very start of a test:
https://sof-ci.01.org/sofpr/PR5340/build11976/devicetest/?model=TGLU_UP_HDA_ZEPHYR&testcase=test-speaker
error: Invalid filename length 1650680879 or ldc file does not match firmware
error: read_entry_from_ldc_file(0x25007) returned -22
error: fetch_entry() failed with: -22, aborting
This happens in about 1 out 50 test runs.
The dictionary is valid because other tests immediately before and after are fine in the exact same configuration.
While the "sof-logger was already dead" error message is in the end the same as #5120 (which was hiding this bug), the symptoms are extremely different.
This caused a number of failures in recent daily runs 10079, 10105 and 10146. It seems Zephyr specific. It's not clear why it's even more rare in PR testing.
10079?model=TGLU_UP_HDA_ZEPHYR&testcase=volume-basic-test-50
10079?model=WHL_UPEXT_HDA_ZEPHYR&testcase=multiple-pipeline-capture-50
10105?model=APL_UP2_NOCODEC_ZEPHYR&testcase=multiple-pipeline-playback-50
10146?model=APL_UP2_NOCODEC_ZEPHYR&testcase=check-capture-50rounds
10146?model=APL_UP2_NOCODEC_ZEPHYR&testcase=multiple-pause-resume-50
10146?model=TGLH_RVP_NOCODEC_ZEPHYR&testcase=check-xrun-injection-playback-10
Daily run 10079:
Start Time: 2022-02-09 22:27:36 UTC
Kernel Branch: topic/sof-dev
Kernel Commit: 8bf95cb0
SOF Branch: main
SOF Commit: 9983ab67a9fe
Zephyr Commit: 41a63f48fdc8
DMA alignment fix c11562b for #5120 was between 10079 and 10105
Daily run 10105 was:
Start Time: 2022-02-10 22:27:29 UTC
Kernel Branch: topic/sof-dev
Kernel Commit: 936898a6
SOF Branch: main
SOF Commit: 443b21de4b3f
Zephyr Commit: 5094a6e08cee
Daily run 10146 was:
Kernel Branch: topic/sof-dev
Kernel Commit: 98119478
SOF Branch: main
SOF Commit: b8954754f055
Zephyr Commit: v3.0.0-rc3