Union sloppiness tokens on the PlatformIO path too, survive non-UTF-8 include names

esphome/build_helpers/pch.py

@@ -121,7 +121,12 @@ def _include_closure(src_dir: Path, roots: Iterable[str]) -> dict[str, bytes]:
             data = f"<unreadable:{st.st_mtime_ns}:{st.st_size}>".encode()
         seen[rel] = data
         parent = posixpath.dirname(rel)
-        stack.extend((inc.decode(), parent) for inc in _INCLUDE_RE.findall(data))
+        stack.extend(
+            # surrogateescape: a non-UTF-8 include name must not abort the
+            # build; it simply will not resolve and ends the walk
+            (inc.decode(errors="surrogateescape"), parent)
+            for inc in _INCLUDE_RE.findall(data)
+        )
     return seen
 
 

esphome/platformio/pch.py.script

@@ -54,7 +54,10 @@ def _include_closure(src_dir: Path, roots: list) -> dict:
             data = f"<unreadable:{st.st_mtime_ns}:{st.st_size}>".encode()
         seen[rel] = data
         parent = posixpath.dirname(rel)
-        stack.extend((inc.decode(), parent) for inc in _INCLUDE_RE.findall(data))
+        stack.extend(
+            (inc.decode(errors="surrogateescape"), parent)
+            for inc in _INCLUDE_RE.findall(data)
+        )
     return seen
 
 
@@ -264,6 +267,14 @@ def _setup_pch() -> None:
     ):
         if key not in os.environ:
             projenv["ENV"][key] = value  # noqa: F821
+    sloppiness = os.environ.get("CCACHE_SLOPPINESS")
+    if sloppiness is not None:
+        missing = [t for t in ("pch_defines", "time_macros") if t not in sloppiness]
+        if missing:
+            # Without these ccache declines every pch-consuming compile;
+            # union rather than override so the user's own tokens survive
+            projenv["ENV"]["CCACHE_SLOPPINESS"] = ",".join((sloppiness, *missing))  # noqa: F821
+            print(f"ESPHome: adding {','.join(missing)} to CCACHE_SLOPPINESS for the pch")
 
     # Prepended so it is processed before the build_src_flags -include
     # entries: GCC only uses a .gch while no other tokens have been seen.

tests/unit_tests/build_helpers/test_pch.py

@@ -166,3 +166,12 @@ def test_include_closure_raises_when_identity_unknown(
     with pytest.raises(OSError, match="stat failed"):
         pch._include_closure(_FakeSrcDir(), ["a.h"])
     assert "Could not read a.h" in caplog.text
+
+
+def test_include_closure_survives_non_utf8_include_name(tmp_path: Path) -> None:
+    """A non-UTF-8 quoted include must not abort the build; it simply does
+    not resolve and ends the walk."""
+    (tmp_path / "a.h").write_bytes(b'#include "bad\xff.h"\n#include "b.h"\n')
+    (tmp_path / "b.h").write_text("")
+    closure = pch._include_closure(tmp_path, ["a.h"])
+    assert set(closure) == {"a.h", "b.h"}

tests/unit_tests/test_platformio_pch_script.py

@@ -273,6 +273,16 @@ def test_copy_pch_script(tmp_path: Path) -> None:
     assert (tmp_path / "pch.py").read_text() == _SCRIPT.read_text()
 
 
+def test_pch_script_unions_user_sloppiness(
+    tmp_path: Path, capsys: pytest.CaptureFixture[str]
+) -> None:
+    """A user CCACHE_SLOPPINESS without the pch tokens gets them unioned on,
+    mirroring ccache_pch_env, or every src TU is a permanent miss."""
+    scons_env = _run_script(tmp_path, env_vars={"CCACHE_SLOPPINESS": "locale"})
+    assert scons_env["ENV"]["CCACHE_SLOPPINESS"] == "locale,pch_defines,time_macros"
+    assert "adding pch_defines,time_macros" in capsys.readouterr().out
+
+
 def test_pch_script_nobuild_without_projenv_is_noop(tmp_path: Path) -> None:
     """-t nobuild never exports projenv; the script must not abort."""
     proj = tmp_path / "dev"