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WL1271 network failing over time

Other Parts Discussed in Thread: WL1271

We've got a WL1271 hooked up to an AM335X, running linux (3.2).

Running the newest (SP7) drivers, and the newest firmware (6.3.10.0.139).

We've been seeing some very weird behavior with our devices.

They will connect to the network and be running along fine, and then they will start experiencing beacon loss messages.  After that at some point they will lose network connectivity.  Ifconfig will return no IP, and a service networking restart command will fail to connect to a DHCP server and get an address (despite DHCP being very much functional on that network - this has also happened on many different networks).

Getting networking working again afterwards is also very difficult - both warm and cold reboots can be ineffective (sometimes full power removal works, but not always).

We are also seeing (on some devices) driver crashes with PLT errors:

[  413.146514] wl12xx: Beacon loss detected.
[  544.101959] wl12xx: ERROR Tx stuck (in FW) for 5000 ms. Starting recovery
[  544.109344] ------------[ cut here ]------------
[  544.114349] WARNING: at /home/batman/temp/build-utils/compat-wireless/drivers/net/wireless/wl12xx/main.c:1437 wl12xx_queue_recovery_work+0x34/0x9c [wl12xx]()
[  544.129119] Modules linked in: hci_uart(O) bluetooth(O) wl12xx(O) mac80211(O) cfg80211(O) wl12xx_sdio(O)
[  544.139129] Backtrace: 
[  544.141723] [<c0017dbc>] (dump_backtrace+0x0/0x10c) from [<c03f27d0>] (dump_stack+0x18/0x1c)
[  544.150604]  r6:bf0a1b90 r5:00000009 r4:00000000 r3:c05c12cc
[  544.156585] [<c03f27b8>] (dump_stack+0x0/0x1c) from [<c003d9a4>] (warn_slowpath_common+0x54/0x6c)
[  544.165924] [<c003d950>] (warn_slowpath_common+0x0/0x6c) from [<c003d9e0>] (warn_slowpath_null+0x24/0x2c)
[  544.175964]  r8:00000000 r7:bf0a1e28 r6:cf19d780 r5:cf19d7b0 r4:cf19d780
[  544.182861] r3:00000009
[  544.185638] [<c003d9bc>] (warn_slowpath_null+0x0/0x2c) from [<bf0a1b90>] (wl12xx_queue_recovery_work+0x34/0x9c [wl12xx])
[  544.197143] [<bf0a1b5c>] (wl12xx_queue_recovery_work+0x0/0x9c [wl12xx]) from [<bf0a1f2c>] (wl12xx_tx_watchdog_work+0x104/0x148 [wl12xx])
[  544.210021]  r4:cf19e270 r3:c05c12e8
[  544.213867] [<bf0a1e28>] (wl12xx_tx_watchdog_work+0x0/0x148 [wl12xx]) from [<c0050af8>] (process_one_work+0x11c/0x364)
[  544.225097]  r6:cf47f200 r5:cf015ec0 r4:cf19e270 r3:60000013
[  544.231048] [<c00509dc>] (process_one_work+0x0/0x364) from [<c0051458>] (worker_thread+0x17c/0x310)
[  544.240570] [<c00512dc>] (worker_thread+0x0/0x310) from [<c0055b7c>] (kthread+0x8c/0x94)
[  544.249084] [<c0055af0>] (kthread+0x0/0x94) from [<c0040804>] (do_exit+0x0/0x65c)
[  544.256958]  r6:c0040804 r5:c0055af0 r4:cf01ded4
[  544.261810] ---[ end trace ec0ff4f19e27daac ]---
[  544.298614] wl12xx: watchdog interrupt received! continue with recovery
[  544.305694] wl12xx: Reading FW panic log
[  544.339172] wl12xx: Hardware recovery in progress. FW ver: Rev 6.3.10.0.139
[  544.368652] wl12xx: pc: 0xbc4
[  544.371856] wl12xx: removing interface c4:54:44:14:3e:27
[  544.392456] wl12xx_set_power(..., on=0, vdd=0) entered
[  544.422851] ieee80211 phy0: Hardware restart was requested
[  544.429107] wl12xx: state: 0
[  544.452331] wl12xx_set_power(..., on=1, vdd=21) entered
[  544.879302] wl12xx: firmware booted (Rev 6.3.10.0.139)
[  544.981597] wl12xx: Association completed.
[  545.008026] wl12xx: ERROR no active RX BA session on tid: 0
[  545.014007] wl12xx: ERROR no active RX BA session on tid: 5

Any suggestions?