Group runtime timers and flags to recover nRF52 repeater RAM

examples/simple_repeater/MyMesh.h

@@ -355,53 +355,59 @@ class MyMesh : public mesh::Mesh, public CommonCLICallbacks
   size_t serial_log_remaining = 0;
   size_t serial_log_pending_size = 0;
   char serial_log_pending[640];
+  int serial_acl_next = -1;
+  int serial_acl_count = 0;
+  int serial_recent_next = -1;
+  int serial_recent_count = 0;
+  SimpleMeshTables::RecentRepeaterInfo serial_recent_cursor;
+  int serial_recent_cursor_index = -1;
   bool serial_log_active = false;
   bool serial_log_eof_pending = false;
   bool serial_log_skip_line = false;
-  int serial_acl_next = -1;
-  int serial_acl_count = 0;
   bool serial_acl_header = false;
-  int serial_recent_next = -1;
-  int serial_recent_count = 0;
   bool serial_recent_header = false;
   bool serial_recent_has_cursor = false;
-  SimpleMeshTables::RecentRepeaterInfo serial_recent_cursor;
-  int serial_recent_cursor_index = -1;
+#endif
+  // Runtime only: group scalar timers and flags to avoid gaps before aligned
+  // members. No persisted preferences or queue capacities depend on this order.
+  uint64_t uptime_millis;
+  uint64_t last_battery_alert_sent;
+#if MESH_ENABLE_HOST_CLI
+  uint64_t host_cli_nonce;
+  uint64_t host_cli_claim_challenge;
 #endif
   uint32_t last_millis;
-  uint64_t uptime_millis;
   unsigned long next_local_advert, next_flood_advert;
+  uint32_t primary_radio_mutation_generation = 0;
+  uint32_t radio_reply_deadline = 0;
+#if MESH_ENABLE_HOST_CLI
+  unsigned long host_cli_deadline;
+  unsigned long host_cli_claim_emit_at;
+#endif
+  uint32_t pending_self_advert_delay;
+  unsigned long next_battery_alert_check;
+  unsigned long next_recent_repeater_sweep;
   mesh::DeferredCliCommand deferred_cli_command;
   mesh::RemoteCliReplyCache remote_cli_reply_cache;
   mesh::ReplayResetNonce replay_reset_nonce;
-  bool replay_clock_set = false;
   mesh::TempRadioReplyBarrier temp_radio_reply_barrier;
-  uint32_t primary_radio_mutation_generation = 0;
-  bool primary_radio_mutation_starts_temp = false;
-  uint32_t radio_reply_deadline = 0;
-  bool radio_reply_secondary = false;
   void finishRadioReply(bool delivered);
   void serviceRadioReplyDeadline();
   TransportKey deferred_cli_reply_scope;
+  mesh::RxInactivityWatchdog rx_inactivity_watchdog;
+  mesh::RepeaterRadioTiming radio_timing;
+  mesh::Packet* pending_battery_alert_packet;
+  bool replay_clock_set = false;
+  bool primary_radio_mutation_starts_temp = false;
+  bool radio_reply_secondary = false;
   bool deferred_cli_reply_scoped;
 #if MESH_ENABLE_HOST_CLI
   bool host_cli_waiting;
   bool host_cli_claimed;
   bool host_cli_claim_emit;
-  unsigned long host_cli_deadline;
-  unsigned long host_cli_claim_emit_at;
-  uint64_t host_cli_nonce;
-  uint64_t host_cli_claim_challenge;
 #endif
-  uint32_t pending_self_advert_delay;
   bool pending_self_advert;
   bool pending_self_advert_flood;
-  unsigned long next_battery_alert_check;
-  mesh::RxInactivityWatchdog rx_inactivity_watchdog;
-  mesh::RepeaterRadioTiming radio_timing;
-  unsigned long next_recent_repeater_sweep;
-  uint64_t last_battery_alert_sent;
-  mesh::Packet* pending_battery_alert_packet;
   bool battery_alert_sent;
   bool _logging;
 #ifdef DISPLAY_ACTIVITY_DASHBOARD

src/helpers/CommonCLI.h

@@ -944,7 +944,6 @@ class CommonCLI {
 #if MESH_ENABLE_EMERGENCY_POWER
   FILESYSTEM* _emergency_power_fs = nullptr;
   mesh::emergencypower::State _emergency_power;
-  bool _emergency_radio_sleeping = false;
   void loadEmergencyPower(FILESYSTEM* fs);
   bool saveEmergencyPower(const mesh::emergencypower::Settings& settings);
   void loopEmergencyPower();
@@ -968,7 +967,6 @@ class CommonCLI {
   SensorManager* _sensors;
   RegionMap* _region_map;
   uint32_t _media_regions_retry_ms = 0;
-  bool _media_regions_ready = false;
   static bool mediaMeshRegionStoreMissing(FILESYSTEM* fs);
   void recoverMediaMeshRegions();
   static bool updateMediaMeshScope(void* context, bool enable, bool commit);
@@ -989,6 +987,12 @@ class CommonCLI {
   bool _observer_save_result_known = false;
   bool _observer_save_succeeded = false;
 #endif
+  // Runtime flags share padding; persisted NodePrefs retains its own layout.
+  bool _media_regions_ready = false;
+#if MESH_ENABLE_EMERGENCY_POWER
+  bool _emergency_radio_sleeping = false;
+#endif
+  uint8_t _rx_settings_pending = 0;
   bool _com_prefs_needs_upgrade = false;  // old-format legacy prefs detected; rewrite once after load
   bool _common_save_result_known = false;
   bool _common_save_succeeded = false;
@@ -1004,7 +1008,6 @@ class CommonCLI {
     RxGain = 1, RxPowerSaving = 2, RxSideDetectors = 4, RxRfRx = 8,
     RxPendingMask = 15, RxRfRxDisabled = 128
   };
-  uint8_t _rx_settings_pending = 0;
   uint32_t _rx_settings_retry_at = 0;
   uint32_t _prefs_save_failures = 0;
   mesh::RadioProfileCLI _radio_profiles;

src/helpers/EmergencyPowerPolicy.h

@@ -44,18 +44,19 @@ inline bool decode(const uint8_t* in, size_t size, Settings& settings) {
 }
 
 struct State {
-  Settings settings;
+  // Runtime only: keep aligned timers together without packing accesses.
   uint32_t sampledAt = 0;
-  uint16_t millivolts = 0;
-  uint8_t percentage = 0;
-  bool sampled = false;
-  bool valid = false;
-  bool lowBattery = false;
   uint32_t phaseMs = 0;
   uint32_t lastTick = 0;
   uint32_t activationStarted = 0;
   uint32_t awakeStarted = 0;
   uint32_t awakeDuration = 0;
+  uint16_t millivolts = 0;
+  uint8_t percentage = 0;
+  Settings settings;
+  bool sampled = false;
+  bool valid = false;
+  bool lowBattery = false;
   bool activationHold = false;
 
   void begin(const Settings& loaded, uint32_t now) {
@@ -118,5 +119,7 @@ struct State {
     return phase < AwakeWindowMs ? 0 : HourMs - phase;
   }
 };
+static_assert(sizeof(State) <= 32, "Emergency timers must retain their compact RAM layout");
+static_assert(alignof(State) >= alignof(uint32_t), "Emergency timers must remain aligned");
 
 }} // namespace mesh::emergencypower

test/test_emergency_power.py

@@ -174,6 +174,7 @@ class EmergencyPowerTests(unittest.TestCase):
             start = header.index(marker)
             return header[start:header.index("#endif", start) + len("#endif")]
         private = api_block("#if MESH_ENABLE_EMERGENCY_POWER\n  FILESYSTEM* _emergency_power_fs")
+        private += "\n" + api_block("#if MESH_ENABLE_EMERGENCY_POWER\n  bool _emergency_radio_sleeping")
         public = api_block("#if MESH_ENABLE_EMERGENCY_POWER\n  uint32_t emergencySleepMilliseconds")
         implementation = (ROOT / "src/helpers/CommonCLI_Emergency.cpp").read_text(encoding="ascii")
         implementation = re.sub(r"^#include[^\n]*\n", "", implementation, flags=re.MULTILINE)