[code sync] Merge code from sonic-net/sonic-platform-daemons:202605 to 202608 - #82
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Aug 4, 2026
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…andling (#866) #### Description Enhance the DPU auto-recovery state machine in chassisd to fix race conditions between concurrent operations (shutdown/reboot vs power-cycle), improve correctness of the default behavior, and refactor for maintainability. Key changes: - Read `dpu_auto_recovery` from `DEVICE_METADATA` instead of `FEATURE` table - Default to **disabled** when the `dpu_auto_recovery` field is missing (safer default) - Direct transition to `ManualIntervention` when auto-recovery is disabled (skip `WaitForSelfRecovery`) - PCIe detach/reattach around power-cycle for clean hardware reset - Check `reset_limit` before issuing power-cycle to avoid wasted resets - Acquire state transition lock during power-cycle to prevent races with gnoi shutdown/reboot - Re-check `transition_in_progress` after lock acquisition to close TOCTOU window - Abort power-cycle if lock cannot be acquired (another operation in progress) - Unify field name: use `transition_in_progress` (drop legacy `state_transition_in_progress`) - Ignore `transition_type == 'recovery'` so chassisd does not suppress itself - Refactor: extract `_process_single_dpu_recovery` to reduce `update_dpu_recovery_state` size - Refactor: extract `_enter_booting`/`_enter_ready`/`_enter_wait_for_self_recovery` transition helpers - Refactor: extract `_should_handle_hw_offline` for offline-state guard clarity - Refactor: extract `_handle_boot_timeout_expired` shared by Booting and PowerCycle states Depends on sonic-net/sonic-platform-common PR for `get_module_state_transition`/`set_module_state_transition`/`clear_module_state_transition` platform API. #### Motivation and Context Addresses review comments from PR #815. The DPU auto-recovery feature had several race conditions: 1. **Power-cycle recovery vs planned shutdown**: If gnoi initiated a shutdown while chassisd was about to power-cycle, both operations would conflict, potentially bricking the DPU. 2. **TOCTOU between check and lock**: A gap between checking if a transition was in progress and acquiring the lock allowed concurrent operations to slip through. 3. **Default-enabled risk**: Missing `dpu_auto_recovery` field defaulted to enabled, which could cause unexpected power-cycles on systems without explicit configuration. #### How Has This Been Tested? 1. **Unit tests**: Comprehensive unit tests added in `tests/test_dpu_auto_recovery.py` covering all state transitions, race conditions, lock acquisition failures, and edge cases. 2. **On-device testing** on a **202605/master** image (SmartSwitch), via the sonic-mgmt `smartswitch/platform_tests` suite, which exercises the DPU failure-mode / auto-recovery scenarios: - Control-plane-down → auto-recovery power-cycle → DPU returns to `ready_status=true` - Auto-recovery disabled → direct `ManualIntervention` (no power-cycle) - Power-cycle with lock contention (gnoi shutdown holding the transition lock) - TOCTOU re-check after lock acquisition - Self-suppression (`transition_type == 'recovery'` exclusion) - Unrecoverable state after `reset_limit` exceeded; admin-down/up clears it - NPU crash → bulk power-cycle of all admin-up DPUs **Final results (202605/master):** the end-to-end auto-recovery path was confirmed — chassisd power-cycled the failed DPU and it returned to `ready_status=true`. After the accompanying fixes (device `DEVICE_METADATA.dpu_auto_recovery` YANG leaf, the `module_base` `recovery` transition-timeout default, and a recovery-timeout bump), `test_dpu_failure_modes` finished **5 passed / 2 failed / 1 skipped (0 errored)**. Both remaining failures were environmental/test-harness — a `databasedpu` container inactive at test start, and a config-reload case that ran on pre-fix test code — not auto-recovery regressions. 3. **Verified**: No regressions on remaining DPUs (remained in Ready state throughout DPU0 destructive testing) Signed-off-by: Sonic Build Admin <sonicbld@microsoft.com> #### Additional Information (Optional)
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