Warn only on corrupt reports, carry the traceback, name the file

Structural corruption at any level (containers or non-numeric leaves)
warns as malformed; a well-shaped report simply lacking DRAM/DIRAM is a
variant difference and stays at debug, so healthy builds on other
targets cannot train users to ignore the warning channel. The backstop
warning carries exc_info so a field report is actionable without -v,
and the image_size warning names its file. Tests pin each message
distinctly.

esphome/espidf/size_summary.py

@@ -93,9 +93,12 @@ def print_summary(size_json: Path, partitions_csv: Path | None) -> None:
         # Backstop for shapes the named guards below miss; warning so a
         # regression here cannot go missing indefinitely
         _LOGGER.warning(
-            "Skipping size summary for %s: %s: %s", size_json, type(e).__name__, e
+            "Skipping size summary for %s: %s: %s",
+            size_json,
+            type(e).__name__,
+            e,
+            exc_info=True,
         )
-        _LOGGER.debug("Size summary failure detail", exc_info=True)
 
 
 def _print_summary(size_json: Path, partitions_csv: Path | None) -> None:
@@ -114,7 +117,7 @@ def _print_summary(size_json: Path, partitions_csv: Path | None) -> None:
 
     if (ram := _ram_line(data, size_json)) is not None:
         print(ram)
-    if (flash := _flash_line(data, partitions_csv)) is not None:
+    if (flash := _flash_line(data, size_json, partitions_csv)) is not None:
         print(flash)
 
 
@@ -139,17 +142,24 @@ def _ram_line(data: dict, size_json: Path) -> str | None:
     total = _dict_get(ram_region, "size")
     if _is_number(used) and _is_number(total) and total > 0:
         return f"RAM:   {_format_bar(int(used), int(total))}"
-    if _present_but_not_dict(memory_types) or _present_but_not_dict(ram_region):
+    malformed = (
+        _present_but_not_dict(memory_types)
+        or _present_but_not_dict(ram_region)
+        or any(v is not None and not _is_number(v) for v in (used, total))
+    )
+    if malformed:
         # A structurally corrupt report, not a variant without the region
         _LOGGER.warning("Skipping RAM summary: malformed memory_types in %s", size_json)
     else:
-        _LOGGER.warning(
+        # A variant may name its RAM region differently; healthy builds
+        # must not warn
+        _LOGGER.debug(
             "Skipping RAM summary: no usable DRAM/DIRAM region in %s", size_json
         )
     return None
 
 
-def _flash_line(data: dict, partitions_csv: Path | None) -> str | None:
+def _flash_line(data: dict, size_json: Path, partitions_csv: Path | None) -> str | None:
     """The formatted Flash line, or None (already logged) to skip it.
 
     Owns both sides of the bar, so nothing after a print can raise: the
@@ -157,7 +167,7 @@ def _flash_line(data: dict, partitions_csv: Path | None) -> str | None:
     """
     image_size = data.get("image_size")
     if not _is_number(image_size):
-        _LOGGER.warning("Skipping Flash summary: no usable image_size")
+        _LOGGER.warning("Skipping Flash summary: no usable image_size in %s", size_json)
         return None
     if partitions_csv is None:
         _LOGGER.debug("Skipping Flash summary: no partition table given")

tests/unit_tests/test_size_summary.py

@@ -213,15 +213,32 @@ def test_print_summary_nested_bad_shapes_never_raise(
     caplog: pytest.LogCaptureFixture,
     payload: dict,
 ) -> None:
-    """Bad nested shapes hit the named RAM guard, not the blanket backstop."""
+    """Corrupt nested shapes hit the named malformed guard, not the blanket."""
     size_json = _write_size_json(tmp_path, payload)
     print_summary(size_json, None)
     # No half-formed bar for CI to scrape; every payload fails before printing
     assert capsys.readouterr().out == ""
-    assert "Skipping RAM summary" in caplog.text
+    assert "malformed memory_types" in caplog.text
     assert "Skipping size summary for" not in caplog.text
 
 
+def test_print_summary_absent_region_stays_quiet(
+    tmp_path: Path,
+    capsys: pytest.CaptureFixture[str],
+    caplog: pytest.LogCaptureFixture,
+) -> None:
+    """A well-shaped report without DRAM/DIRAM is a variant difference, not
+    a broken artifact: debug, never a per-build warning."""
+    size_json = _write_size_json(tmp_path, {"memory_types": {}, "image_size": 1})
+    with caplog.at_level(logging.DEBUG, logger="esphome.espidf.size_summary"):
+        print_summary(size_json, None)
+    assert "RAM:" not in capsys.readouterr().out
+    assert "no usable DRAM/DIRAM region" in caplog.text
+    assert not [
+        r for r in caplog.records if r.levelno >= logging.WARNING and "RAM" in r.message
+    ]
+
+
 def test_print_summary_non_numeric_image_size_warns_by_name(
     tmp_path: Path,
     capsys: pytest.CaptureFixture[str],