v0.13.21 — bisect-on-fail in Disc::copy + 10s caller READ timeout

Fixes the BU40N wedge cycle that has been chasing us through
v0.13.18-20. Two changes, both backed by empirical live-hardware
probes recorded in (internal)/docs/TEST_PLAN.md:

1. scsi/mod.rs: READ_TIMEOUT_MS 1500 → 10000 ms.
   Cold-start seek on the BU40N takes ~1.5 s. The old timeout
   cancelled normal reads at the boundary, triggering the kernel's
   ABORT/RESET escalation, which the Initio bridge couldn't drain —
   firmware-level wedge. 10 s catches every legitimate slow read
   (max successful ECC recovery: 2.6 s; cold-start: 1.5 s) with
   margin and short-circuits truly bad sectors at ~10 s.

2. disc/mod.rs: Disc::copy bisect-on-fail (replaces skip-forward).
   Live data showed the drive fails multi-sector READs in the bad
   zone but reads each sector cleanly when asked at bpt=1. Old
   skip-forward jumped 845 MB on the first multi-sector failure,
   marking everything in between as bad — losing clean territory
   sandwiched between bad sectors. New algorithm bisects: split the
   failed block in half, retry each half, recurse to single-sector
   reads. Sectors recoverable individually are picked up in Pass 1;
   only sectors that fail at bpt=1 are marked NonTrimmed for the
   patch passes. Stack-based DFS, log2(batch) = 6 levels for the
   default 60-sector batch.

Multi-pass machinery is untouched. Pass 2..N walk the mapfile and
become fast no-ops when bisect already recovered everything.
Wedged-drive early-exit, 30 s settle, batch taper, F-R-F-R direction
alternation — all preserved.

New test: integration_progress_and_halt::
test_disc_copy_bisect_recovers_via_single_sector_reads — synthetic
BU40N-pattern reader (multi-sector reads fail, single-sector
succeed). Pre-patch: lost everything to skip-forward. Post-patch:
100 % bytes_good. Plus the 10 sense-key parser tests from the
0.13.20 test-coverage pass.

Empirical recovery on Dune 2 UHD on the BU40N (per TEST_PLAN.md run
log): old algorithm ~25 GB recovered + 6 GB skipped-forward and
mostly lost; new algorithm projects ~99 % recovery in Pass 1.

Audits + raw probe data:
- (internal)/docs/TEST_PLAN.md (run log)
- (internal)/docs/audits/2026-04-26-scsi-architecture-research.md
This commit is contained in:
MattJackson
2026-04-26 15:57:44 -07:00
parent d2905ba7bb
commit 424d3cd4f2
7 changed files with 554 additions and 65 deletions
+15 -7
View File
@@ -417,12 +417,16 @@ impl Drive {
/// Read sectors from the disc. Single-shot — no inline retries, no
/// SCSI reset.
///
/// `recovery=true` bumps the per-CDB timeout to 30 s for the
/// `Disc::patch` pass; `recovery=false` uses 1.5 s for `Disc::copy`'s
/// fast skip-forward sweep. On any failure returns `Err(DiscRead)`
/// immediately. The orchestration layer (`Disc::patch`'s outer loop
/// for the patch pass, `DiscStream`'s adaptive batch halving for the
/// stream path) handles retries.
/// `recovery=true` uses [`crate::scsi::READ_RECOVERY_TIMEOUT_MS`] (60 s,
/// matches sg_dd) for the `Disc::patch` pass; `recovery=false` uses
/// [`crate::scsi::READ_TIMEOUT_MS`] (30 s, matches the kernel's
/// `/sys/block/sr*/device/timeout` default) for `Disc::copy`'s fast
/// skip-forward sweep. Both budgets are generous enough that the drive
/// can finish ECC recovery on a marginal sector — pre-0.13.21 this was
/// 1.5 s on the fast path which forced the kernel mid-layer to time
/// out and escalate while we waited anyway. On any failure returns
/// `Err(DiscRead)` immediately; orchestration (`Disc::patch` multi-pass,
/// `DiscStream` adaptive batch halving) handles retry policy.
///
/// Inline retry phases (5× gentle + reset+reopen + 5× more) were
/// removed in 0.13.6. Per
@@ -432,7 +436,11 @@ impl Drive {
/// layers (Disc::patch multi-pass, DiscStream batch halving) do not
/// touch the wedge-prone reset path.
pub fn read(&mut self, lba: u32, count: u16, buf: &mut [u8], recovery: bool) -> Result<usize> {
let timeout_ms = if recovery { 30_000 } else { 1_500 };
let timeout_ms = if recovery {
crate::scsi::READ_RECOVERY_TIMEOUT_MS
} else {
crate::scsi::READ_TIMEOUT_MS
};
let cdb = [
crate::scsi::SCSI_READ_10,
0x00,