🚧 Add Wokwi ESP32 simulator CI workflow with Playwright web interface testing, boot validation scenarios, combined firmware image support, and network debugging

.github/workflows/wokwi-test.yml

@@ -0,0 +1,301 @@
+name: Wokwi ESP32 Simulation Test
+
+on:
+  push:
+    branches: [ "mdev", "copilot/**" ]
+  pull_request:
+    branches: [ "mdev" ]
+  workflow_dispatch:
+
+jobs:
+  wokwi-test:
+    name: Test WLED with Wokwi Simulator
+    runs-on: ubuntu-22.04
+
+    steps:
+      - name: Checkout code
+        uses: actions/checkout@v4
+
+      - name: Cache pip
+        uses: actions/cache@v4
+        with:
+          path: ~/.cache/pip
+          key: ${{ runner.os }}-pip-${{ hashFiles('**/requirements.txt') }}
+          restore-keys: |
+            ${{ runner.os }}-pip-
+
+      - name: Cache PlatformIO
+        uses: actions/cache@v4
+        with:
+          path: ~/.platformio
+          key: ${{ runner.os }}-pio-esp32_V4_wokwi_debug
+
+      - name: Set up Python
+        uses: actions/setup-python@v5
+        with:
+          python-version: '3.9'
+
+      - name: Install PlatformIO
+        run: pip install -r requirements.txt
+
+      - name: Set up Node.js
+        uses: actions/setup-node@v4
+        with:
+          node-version: '20'
+          cache: 'npm'
+
+      - name: Install Node.js dependencies
+        run: npm ci
+
+      - name: Build web UI
+        run: npm run build
+
+      - name: Build firmware for ESP32
+        env:
+          WLED_RELEASE: True
+        run: pio run -e esp32_V4_wokwi_debug
+
+      - name: Install Wokwi CLI
+        run: |
+          curl -L https://wokwi.com/ci/install.sh | sh
+          echo "Wokwi CLI installed to: $HOME/.wokwi-ci/bin/"
+          ls -la "$HOME/.wokwi-ci/bin/" || echo "Directory not found"
+          export PATH="$HOME/.wokwi-ci/bin:$PATH"
+          wokwi-cli --version || echo "Warning: wokwi-cli not accessible"
+
+      - name: Prepare firmware for Wokwi
+        run: ./test/wokwi/prepare-firmware.sh esp32_V4_wokwi_debug
+
+      - name: Debug - Verify token is set
+        run: |
+          if [ -z "$WOKWI_CLI_TOKEN" ]; then
+            echo "❌ ERROR: WOKWI_CLI_TOKEN is not set"
+            echo "Please configure WOKWI_CLI_TOKEN as a repository secret"
+            exit 1
+          else
+            echo "✅ WOKWI_CLI_TOKEN is set (length: ${#WOKWI_CLI_TOKEN} characters)"
+          fi
+        env:
+          WOKWI_CLI_TOKEN: ${{ secrets.WOKWI_CLI_TOKEN }}
+
+      - name: Quick boot validation with scenario
+        working-directory: test/wokwi
+        env:
+          WOKWI_CLI_TOKEN: ${{ secrets.WOKWI_CLI_TOKEN }}
+        run: |
+          # Create log directory
+          mkdir -p logs
+
+          # Add Wokwi CLI to PATH for this step
+          export PATH="$HOME/.wokwi-ci/bin:$PATH"
+
+          # Verify combined firmware image exists (recommended approach for Wokwi)
+          echo "Checking for combined firmware image..."
+          if [ ! -f "firmware-combined.bin" ]; then
+            echo "❌ ERROR: firmware-combined.bin not found in $(pwd)"
+            echo "Available files:"
+            ls -la
+            exit 1
+          fi
+          echo "✅ firmware-combined.bin found ($(du -h firmware-combined.bin | cut -f1))"
+
+          if [ -f "firmware.elf" ]; then
+            echo "✅ firmware.elf found ($(du -h firmware.elf | cut -f1))"
+          else
+            echo "⚠️  firmware.elf not found (optional for simulation)"
+          fi
+
+          # Verify combined firmware image structure
+          echo ""
+          echo "Verifying combined firmware image structure..."
+          python3 <<'EOF'
+          import sys
+          try:
+              with open('firmware-combined.bin', 'rb') as f:
+                  data = f.read()
+
+              size_mb = len(data) / 1024 / 1024
+              print(f"✓ Image size: {len(data)} bytes ({size_mb:.2f} MB)")
+
+              # Check bootloader at 0x1000
+              if len(data) > 0x1000 and data[0x1000] == 0xe9:
+                  print("✓ Bootloader found at 0x1000 (magic byte: 0xe9)")
+              else:
+                  print("⚠ Bootloader magic byte not found at 0x1000")
+                  sys.exit(1)
+
+              # Check partition table at 0x8000  
+              if len(data) > 0x8000 and data[0x8000:0x8002] == b'\xaa\x50':
+                  print("✓ Partition table found at 0x8000 (magic: 0xaa50)")
+              else:
+                  print("⚠ Partition table magic not found at 0x8000")
+                  sys.exit(1)
+
+              # Check application at 0x10000
+              if len(data) > 0x10000 and data[0x10000] == 0xe9:
+                  print("✓ Application found at 0x10000 (magic byte: 0xe9)")
+              else:
+                  print("⚠ Application magic byte not found at 0x10000")
+                  sys.exit(1)
+
+              print("✅ Combined firmware image structure is valid")
+
+          except Exception as e:
+              print(f"❌ ERROR verifying combined image: {e}")
+              sys.exit(1)
+          EOF
+
+          if [ $? -ne 0 ]; then
+            echo "❌ Combined firmware image verification failed"
+            echo "Hex dump of first 256 bytes:"
+            hexdump -C firmware-combined.bin | head -16
+            exit 1
+          fi
+
+          echo ""
+          echo "Running quick boot check scenario (15 seconds)..."
+          echo "Wokwi CLI location: $(which wokwi-cli || echo 'NOT FOUND')"
+          echo "Wokwi CLI version:"
+          wokwi-cli --version || echo "Warning: Could not get version"
+          echo ""
+
+          # Run boot check with increased timeout to account for startup time
+          # Using 30 second timeout for a 15 second scenario to allow for network delays
+          # Capture serial output (stdout) and Wokwi CLI diagnostics (stderr) separately
+          if wokwi-cli --timeout 30000 --scenario scenarios/boot-check.yaml . > logs/boot-check-serial.log 2>logs/boot-check.log; then
+            echo "✅ Boot check passed - firmware boots without crashes"
+            echo ""
+            echo "=== Boot check serial output (last 50 lines) ==="
+            tail -50 logs/boot-check-serial.log
+            echo ""
+            echo "=== Boot check CLI log (last 50 lines) ==="
+            tail -50 logs/boot-check.log
+          else
+            EXIT_CODE=$?
+            echo "❌ Boot check failed with exit code $EXIT_CODE"
+            echo ""
+            echo "=== Boot check CLI log ==="
+            cat logs/boot-check.log
+            echo ""
+            echo "=== Boot check serial output ==="
+            cat logs/boot-check-serial.log
+
+            # Check if it's a WebSocket connection error (code 1006)
+            if grep -q "code 1006" logs/boot-check.log || grep -q "Connection.*closed" logs/boot-check.log; then
+              echo ""
+              echo "⚠️  WebSocket connection error detected (code 1006)"
+              echo "This is typically a transient network issue with Wokwi's API."
+              echo "The workflow will continue with the full simulation test."
+              echo "If this persists, check Wokwi service status or network connectivity."
+              # Don't fail - this might be a transient issue
+            else
+              # Other errors should fail the build
+              exit 1
+            fi
+          fi
+
+      - name: Install Playwright browsers
+        run: npx playwright install --with-deps chromium
+
+      - name: Start Wokwi simulator in background
+        env:
+          WOKWI_CLI_TOKEN: ${{ secrets.WOKWI_CLI_TOKEN }}
+        run: |
+          cd test/wokwi
+          # Create log directory
+          mkdir -p logs
+
+          # Export the token so it's available to child processes
+          export WOKWI_CLI_TOKEN
+
+          # Add PATH for wokwi-cli
+          export PATH="$HOME/.wokwi-ci/bin:$PATH"
+
+          # Start simulator in background with a 90 second timeout
+          # Serial output (stdout) goes to serial.log
+          # Wokwi CLI diagnostics (stderr) including debug logs go to wokwi.log
+          WOKWI_TIMEOUT=90 ./run-simulator.sh >logs/serial.log 2>logs/wokwi.log &
+          WOKWI_PID=$!
+          echo "WOKWI_PID=$WOKWI_PID" >> $GITHUB_ENV
+          echo "Started Wokwi simulator with PID $WOKWI_PID"
+
+          # Wait for simulator to start and web server to be ready
+          echo "Waiting for WLED web server to be ready..."
+          #max_wait=240
+          max_wait=50
+          elapsed=0
+          while [ $elapsed -lt $max_wait ]; do
+            if curl -s -f http://localhost:9080 > /dev/null 2>&1; then
+              echo "✅ Web server is ready on port 9080 after $elapsed seconds!"
+              break
+            fi
+            if curl -s -f http://localhost:8080 > /dev/null 2>&1; then
+              echo "✅ Web server is ready on port 8080 after $elapsed seconds!"
+              break
+            fi
+            if ! kill -0 $WOKWI_PID 2>/dev/null; then
+              echo "❌ Error: Wokwi simulator process died"
+              echo ""
+              echo "=== Last 100 lines of Wokwi CLI log ==="
+              tail -100 logs/wokwi.log || true
+              echo ""
+              echo "=== Last 100 lines of Serial output ==="
+              tail -100 logs/serial.log || true
+              exit 1
+            fi
+            echo "Still waiting... ($elapsed seconds)"
+            sleep 5
+            elapsed=$((elapsed + 5))
+          done
+
+          if [ $elapsed -ge $max_wait ]; then
+            echo "❌ Error: Web server did not start within $max_wait seconds"
+            echo ""
+            echo "=== Last 100 lines of Wokwi CLI log ==="
+            tail -100 logs/wokwi.log || true
+            echo ""
+            echo "=== Last 100 lines of Serial output ==="
+            tail -100 logs/serial.log || true
+            kill $WOKWI_PID || true
+            exit 1
+          fi
+
+          echo "WLED is ready for testing!"
+          echo ""
+          echo "=== First 50 lines of Serial output ==="
+          head -50 logs/serial.log || true
+          echo ""
+          echo "=== Wokwi CLI debug log (network traffic) ==="
+          tail -100 logs/wokwi.log || echo "No wokwi.log available"
+
+      - name: Run Playwright tests
+        run: npm run test:wokwi
+        env:
+          CI: true
+
+      - name: Upload Playwright report
+        uses: actions/upload-artifact@v4
+        if: always()
+        with:
+          name: playwright-report
+          path: playwright-report/
+          retention-days: 7
+
+      - name: Stop Wokwi simulator
+        if: always()
+        run: |
+          if [ ! -z "$WOKWI_PID" ]; then
+            kill $WOKWI_PID || true
+          fi
+
+      - name: Upload test results
+        uses: actions/upload-artifact@v4
+        if: always()
+        with:
+          name: wokwi-test-results
+          path: |
+            test/wokwi/logs/
+            test/wokwi/firmware-combined.bin
+            test-results/
+            playwright-report/
+          retention-days: 7

.gitignore

@@ -28,3 +28,18 @@ compile_commands.json
 /wled00/wled00.ino.cpp
 /wled00/html_*.h
 _codeql_detected_source_root
+
+# Playwright and test artifacts
+/test-results/
+/playwright-report/
+/playwright/.cache/
+
+# Wokwi runtime files
+/test/wokwi/firmware.bin
+/test/wokwi/firmware.elf
+/test/wokwi/firmware-combined.bin
+/test/wokwi/bootloader.bin
+/test/wokwi/partitions.bin
+/test/wokwi/.wokwi/
+/test/wokwi/logs/
+