Merge branch 'platformio-pch-rp2' into platformio-pch-libretiny

esphome/build_gen/arduino8266.py

@@ -1217,7 +1217,7 @@ def write_project(paths: InstalledPaths, ccache: str | None) -> bool:
     # edge (hundreds of edges in a real project)
     lines.append(f"srcflags = {' '.join(src_other + include_flags)}")
     src_cxx_override = None
-    if pch_enabled() and "-include" in cxxflags:
+    if pch_enabled() and any(tok.startswith("-include") for tok in cxxflags):
         # GCC only loads a .gch while no tokens precede it, and the cxx rule
         # expands $cxxflags before $flags: a user -include in build_flags
         # means every TU would silently skip the .gch
@@ -1281,7 +1281,10 @@ def write_project(paths: InstalledPaths, ccache: str | None) -> bool:
             # Relative -include (resolved from the ninja cwd, where the header
             # lives): an absolute path would put the per-device build path on
             # every compile command and defeat cross-device ccache sharing
-            cxx_parts = src_other + [f"-Winvalid-pch -include {PCH_HEADER_NAME}"]
+            # -Wno-error keeps a rejected .gch a warning under user -Werror
+            cxx_parts = src_other + [
+                f"-Winvalid-pch -Wno-error=invalid-pch -include {PCH_HEADER_NAME}"
+            ]
             lines.append(f"srccxxflags = {' '.join(cxx_parts)}")
             src_cxx_override = ("$srccxxflags", gch)
     src_objs = _ninja_compile_edges(

esphome/build_helpers/pch.py

@@ -71,6 +71,9 @@ _CCACHE_PCH_ENV = {
 
 # Both include forms: an angle include resolving under src/ must enter the
 # digest too; ones that do not resolve simply end the walk
+# Compiler failures that clear on their own must not latch the .failed marker
+_TRANSIENT_ERRORS = ("No space left", "Cannot allocate", "Resource temporarily")
+
 _INCLUDE_RE = re.compile(rb'^\s*#\s*include\s+["<]([^">]+)[">]', re.MULTILINE)
 
 
@@ -379,6 +382,9 @@ def prepare_pch(
         # This path latches, so keep the full compiler output recoverable
         _LOGGER.debug("Full pch compile output: %s", error)
         discard_pch(build_dir)
+        if any(m in error for m in _TRANSIENT_ERRORS):
+            # Resource exhaustion clears on its own; retry next build
+            return
         # Skip retries until a header/flag/backend-identity/command change
         failed_marker.write_text(checksum + "\n", encoding="utf-8")
         os.utime(header)

esphome/platformio/pch.py.script

@@ -25,6 +25,9 @@ except Exception as err:  # noqa: BLE001 -- not exported under -t nobuild
 # include-closure recipe, and the checksum/failed-marker stamp flow in sync
 # with build_helpers/pch.py.
 
+# Compiler failures that clear on their own must not latch the .failed marker
+_TRANSIENT_ERRORS = ("No space left", "Cannot allocate", "Resource temporarily")
+
 _INCLUDE_RE = re.compile(rb'^\s*#\s*include\s+["<]([^">]+)[">]', re.MULTILINE)
 _CORE_HEADER = "esphome/core/defines.h"
 
@@ -76,9 +79,12 @@ def _shell_arg(element) -> str:
     except ValueError as err:
         print(f"ESPHome: could not lex flag {arg!r} for the pch: {err}")
         return arg
-    # Anything but exactly one token means the model above is wrong for
-    # this element; pass it through untouched rather than dropping flags
-    return tokens[0] if len(tokens) == 1 else arg
+    if len(tokens) != 1:
+        # The shell-quoting model is wrong for this element; say so rather
+        # than surfacing only as downstream pch warnings
+        print(f"ESPHome: passing flag {arg!r} through unlexed for the pch")
+        return arg
+    return tokens[0]
 
 
 def _compile_gch(cxx, flags, header: Path, gch: Path, proj_dir: Path):
@@ -280,6 +286,9 @@ def _setup_pch() -> None:
             print(error)
             gch.unlink(missing_ok=True)
             sum_path.unlink(missing_ok=True)
+            if any(m in error for m in _TRANSIENT_ERRORS):
+                # Resource exhaustion clears on its own; retry next build
+                return
             # Skip retries until a flag/header/platform change alters the checksum
             failed_marker.write_text(checksum + "\n", encoding="utf-8")
             return

tests/unit_tests/build_gen/test_arduino8266.py

@@ -416,6 +416,19 @@ def test_write_project_pch_identity_unknown_skips_pch(
     assert "Could not establish the pch identity" in caplog.text
 
 
+def test_write_project_pch_skipped_for_joined_force_include_spelling(
+    tmp_path: Path, caplog: pytest.LogCaptureFixture
+) -> None:
+    """GCC also accepts -includefoo.h as one token; the guard must see it."""
+    paths = _make_framework(tmp_path)
+    _set_flags(
+        "-DPIO_FRAMEWORK_ARDUINO_LWIP2_HIGHER_BANDWIDTH_LOW_FLASH", "-includefoo.h"
+    )
+    content = _write_ninja(paths, ccache="/usr/bin/ccache")
+    assert "esphome_pch" not in content
+    assert "prevents the precompiled header" in caplog.text
+
+
 def test_write_project_pch_skipped_when_user_force_include_precedes(
     tmp_path: Path, caplog: pytest.LogCaptureFixture
 ) -> None:
@@ -1799,7 +1812,10 @@ def test_write_project_pch_no_device_path_poison(tmp_path: Path) -> None:
         CORE.build_path = tmp_path / name
         _set_flags("-DPIO_FRAMEWORK_ARDUINO_LWIP2_HIGHER_BANDWIDTH_LOW_FLASH")
         content = _write_ninja(paths, ccache="/usr/bin/ccache")
-        assert "srccxxflags = -Winvalid-pch -include esphome_pch.h" in content
+        assert (
+            "srccxxflags = -Winvalid-pch -Wno-error=invalid-pch "
+            "-include esphome_pch.h" in content
+        )
         sums.append(
             (CORE.relative_pioenvs_path(name) / "esphome_pch.h.gch.sum").read_text()
         )

tests/unit_tests/build_gen/test_espidf.py

@@ -1052,3 +1052,29 @@ def test_prepare_pch_identity_unknown_discards(tmp_path: Path) -> None:
         prepare_pch()
     assert not stale.exists()
     assert not (dev / "build" / "esphome_pch.h.gch.sum").exists()
+
+
+def test_prepare_pch_transient_compiler_failure_does_not_latch(
+    tmp_path: Path,
+) -> None:
+    """ENOSPC-style failures clear on their own; no .failed marker."""
+    from esphome.build_gen.espidf import prepare_pch
+
+    dev = _make_pch_device(tmp_path, "dev_e")
+    CORE.build_path = dev
+    calls = []
+
+    def enospc(cmd, **kwargs):
+        calls.append(cmd)
+        return subprocess.CompletedProcess(
+            cmd, 1, "", "fatal error: No space left on device"
+        )
+
+    with (
+        patch.object(CORE, "name", "test"),
+        patch("esphome.build_helpers.pch.subprocess.run", side_effect=enospc),
+    ):
+        prepare_pch()
+        prepare_pch()
+    assert not (dev / "build" / "esphome_pch.h.gch.failed").exists()
+    assert len(calls) == 2

tests/unit_tests/test_platformio_pch_script.py

@@ -82,6 +82,7 @@ class _FakeSConsEnv(dict):
 def _fake_cxx(
     tmp_path: Path,
     fail: bool = False,
+    fail_msg: str | None = None,
     reject_pch: bool = False,
     probe_exit: int = 0,
 ) -> Path:
@@ -96,7 +97,7 @@ def _fake_cxx(
         'printf -- ---call---\\\\n >> "$0.argv"; printf \'%s\\n\' "$@" >> "$0.argv"\n'
     )
     if fail:
-        body += "echo boom >&2\nexit 1\n"
+        body += f"echo {fail_msg or 'boom'} >&2\nexit 1\n"
     else:
         # Only the c++-header compile has a -o; the load probe has none
         body += 'out=""; prev=""\nfor a in "$@"; do [ "$prev" = "-o" ] && out="$a"; prev="$a"; done\n'
@@ -113,6 +114,7 @@ def _run_script(
     tmp_path: Path,
     flags: list[str] | None = None,
     fail: bool = False,
+    fail_msg: str | None = None,
     reject_pch: bool = False,
     probe_exit: int = 0,
     missing_cxx: bool = False,
@@ -124,7 +126,13 @@ def _run_script(
     src = proj / "src"
     (src / "esphome" / "core").mkdir(parents=True, exist_ok=True)
     (src / "esphome" / "core" / "defines.h").write_text("#define USE_X\n")
-    cxx = _fake_cxx(tmp_path, fail=fail, reject_pch=reject_pch, probe_exit=probe_exit)
+    cxx = _fake_cxx(
+        tmp_path,
+        fail=fail,
+        fail_msg=fail_msg,
+        reject_pch=reject_pch,
+        probe_exit=probe_exit,
+    )
     if missing_cxx:
         cxx = tmp_path / "no-such-gxx"
     args = (proj, src, str(cxx), flags or ["-DX=1"], platform_cls)
@@ -217,6 +225,16 @@ def test_pch_script_sum_is_device_independent(tmp_path: Path) -> None:
     assert sums[0] == sums[1]
 
 
+def test_pch_script_transient_compiler_failure_does_not_latch(
+    tmp_path: Path,
+) -> None:
+    """ENOSPC-style failures clear on their own; no .failed marker."""
+    scons_env = _run_script(tmp_path, fail=True, fail_msg="No space left on device")
+    proj = tmp_path / "dev"
+    assert not (proj / "esphome_pch.h.gch.failed").exists()
+    assert scons_env.prepended == []
+
+
 def test_pch_script_failure_marker_suppresses_retry(
     tmp_path: Path, capsys: pytest.CaptureFixture[str]
 ) -> None: