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AM4378: USB driver is not loaded sometimes

Part Number: AM4378

customer made 20pcs boards, some boards USB module is not initialized during booting up. especially there is one board failure rate up to 40%, that is say power cycle 10 times, there is about 4 times the USB module did not get initialized. 

Is it hardware issue or software issue, please help to identify? if need further debug message, please point us how to get it?

Attach the fail/OK log of the same board. During the test only connected touch screen on USB0.

AM437x USB.zip

  • Hi Tony,

    Does the issue happen on all the 20 boards?

    When the issue happened, please run the following script on the board and provide its output.

    2867.chkusb.sh.txt
    #!/bin/bash
    #
    # Util to check USB subsystem for Linux kernel 3.12+ on TI Sitara devices
    #
    # Copyright (C) 2018 Texas Instruments Incorporated - http://www.ti.com/
    #
    #
    #  Redistribution and use in source and binary forms, with or without
    #  modification, are permitted provided that the following conditions
    #  are met:
    #
    #    Redistributions of source code must retain the above copyright
    #    notice, this list of conditions and the following disclaimer.
    #
    #    Redistributions in binary form must reproduce the above copyright
    #    notice, this list of conditions and the following disclaimer in the
    #    documentation and/or other materials provided with the
    #    distribution.
    #
    #    Neither the name of Texas Instruments Incorporated nor the names of
    #    its contributors may be used to endorse or promote products derived
    #    from this software without specific prior written permission.
    #
    #  THIS SOFTWARE IS PROVIDED BY THE COPYRIGHT HOLDERS AND CONTRIBUTORS
    #  "AS IS" AND ANY EXPRESS OR IMPLIED WARRANTIES, INCLUDING, BUT NOT
    #  LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
    #  A PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE COPYRIGHT
    #  OWNER OR CONTRIBUTORS BE LIABLE FOR ANY DIRECT, INDIRECT, INCIDENTAL,
    #  SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT NOT
    #  LIMITED TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE,
    #  DATA, OR PROFITS; OR BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY
    #  THEORY OF LIABILITY, WHETHER IN CONTRACT, STRICT LIABILITY, OR TORT
    #  (INCLUDING NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE
    #  OF THIS SOFTWARE, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
    
    VERSION=0.3.2
    DTPATH=/proc/device-tree
    DEVPATH=/sys/devices/platform
    KMODPATH="/lib/modules/`uname -r`"
    
    ### ENV
    # $V: debug flag
    # $PLATFORM: force g_plaform if not found in device tree
    
    ### functions ###
    
    # $1 commands to be checked
    check_command() {
        local _lst="$*"
        local _cmd
    
        for _cmd in $_lst; do
            which $_cmd > /dev/null || {
                echo "Error: $_cmd command not found"
                exit 1
            }
        done
    }
    
    # check if the kernel is supported
    # this tool only runs on v4.0+ kernel
    # return 0 - if kernel version >= 4.0
    #        1 - if kernel version < 4.0
    has_supported_kernel() {
    	local _ver
    	local _t
    
        check_command uname
        uname -a
    	_ver=`uname -r`
        _t=${_ver%%.*}
        # 3.x.x or older, unsupported
        [ $_t -ge 4 ] || return 1
        return 0
    }
    
    # define variables for musb entries in sysfs and device tree
    # output variables: USB_DT_PARENT, USB0DT, USB1DT
    #                   USB_DEV_PARENT, USB0DEV, USB1DEV
    query_musb_entries() {
        local _lst
        local _t
        local _intr
    
        check_command find
    
        # find usb entry names in device-tree
        _t=$(find ${DTPATH}/ -maxdepth 2 -name '*47400000*')
        [ -n "$_t" ] && USB_DT_PARENT=$_t || {
            echo "usb parent DT node not found in device-tree"
            exit 1
        }
    
        _lst=$(find ${USB_DT_PARENT}/ -maxdepth 1 -name 'usb@*')
        [ -n "$_lst" ] || {
            echo "usb0 and usb1 DT node not found in device-tree"
            exit 1
        }
    
        # find USB child DT node based on its interrupt number
        for _t in $_lst; do
            [[ -f "${_t}/interrupts" ]] || continue
            _intr=$(hexdump ${_t}/interrupts | head -1 | cut -d' ' -f3)
            case $_intr in
                "1200") USB0DT=$_t;;
                "1300") USB1DT=$_t;;
                *)  echo "unkown usb interrupt number $_intr"
                    exit 1
            esac
        done
    
        # find device names in sysfs
        _t=$(find ${DEVPATH}/ -maxdepth 2 -name '*47400000*')
        [ -n "$_t" ] && USB_DEV_PARENT=$_t || {
            echo "usb device not found in sysfs"
            exit 1
        }
    
        _t=$(find ${USB_DEV_PARENT}/47401400.usb/ -maxdepth 1 -name 'musb-hdrc.*')
        [ -n "$_t" ] && USB0DEV=$_t || echo "usb0 device not found in sysfs"
    
        _t=$(find ${USB_DEV_PARENT}/47401c00.usb/ -maxdepth 1 -name 'musb-hdrc.*')
        [ -n "$_t" ] && USB1DEV=$_t || echo "usb1 device not found in sysfs"
    }
    
    # check if the platform is supported
    # return 0 - if platform is supported
    #        1 - if platform is not supported
    check_platform () {
    	local _hw
    
        check_command grep
        _hw=`cat ${DTPATH}/compatible | tr '\0' ' '`
        DBG_PRINT "DT compatible: $_hw"
    
        if [[ "$_hw" == *"ti,am33xx"* ]]; then
            g_platform="am335x"
        elif [[ "$_hw" == *"ti,am43"* ]]; then
            g_platform="am437x"
        else
            # read from ENV
            g_platform=$PLATFORM
        fi
    
        DBG_PRINT "g_platform: $g_platform"
        case $g_platform in
            "am335x")
                query_musb_entries
                return 0;;
            "am437x")
                USB0DT="$(find -L $DTPATH -name 'usb@48390000')"
                USB1DT="$(find -L $DTPATH -name 'usb@483d0000')"
                return 0;;
            *)
                echo "Unsupported \"$g_platform\""
                return 1;;
        esac
    }
    
    # get kernel config options from /proc/config.gz
    # params $@ - the list of config options to query, without 'CONFIG_'
    # return - the config options settings in /proc/config.gz
    get_kernel_configs() {
        local _opts="$@"
        local _lst=""
        local _t
    
        check_command zcat grep
        for _t in $_opts; do
            [ -z "$_lst" ] &&
                _lst="^CONFIG_${_t}\>" ||
                _lst="${_lst}\|^CONFIG_${_t}\>"
        done
        [ -z "$_lst" ] || zcat /proc/config.gz | grep "$_lst"
    }
    
    # check a kernel CONFIG option
    # params $1 - the config option list returned from get_kernel_config()
    #             if "", directly check $2 from /proc/config.gz
    #        $2 - the config option to check
    #        $3 = '-q', quiet output
    # return 0 - undefined
    #        1 - defined as 'm', kernel module
    #        2 - defined as 'y', kernel builtin
    check_kernel_config() {
        local _cfg
        local _t
    
        [ -n "$2" ] || return 0
    
        if [ -z "$1" ]; then
            check_command zcat
            _cfg=`zcat /proc/config.gz | grep "^$2\>"`
        else
            for _t in $1; do
                [[ "$_t" != "${2}="? ]] || { _cfg=$_t; break; }
            done
        fi
    
        case ${_cfg#*=} in
            "y") return 2;;
            "m") return 1;;
              *) [ "$3" = "-q" ] ||
                  echo "Error: $2 is undefined in kernel config"
              return 0;;
        esac
    }
    
    # check a kernel module
    # $1 - module name, relative path from drivers/, without .ko surfix
    # return 0 - found
    #        1 - error
    check_module() {
        local _modname
        local _moddep
    
        [ -n "$1" ] || return 1
    
        _modname="${KMODPATH}/kernel/drivers/${1}.ko"
        _moddep="${KMODPATH}/modules.dep"
    
        DBG_PRINT "${1}.ko checking..."
        [ -f $_modname ] || {
            echo "Error: $_modname not found."
            echo "       Please ensure 'make module_install' is done properly."
            return 1
        }
    
        DBG_PRINT "${1}.ko found"
        [ -f $_moddep ] || $g_printed_once || {
            echo "Error: $_moddep not found."
            echo "       Please ensure 'make module_install' is done properly."
            g_printed_once=true
        }
    
        DBG_PRINT "${1}.ko moddep checked"
        check_command lsmod basename tr
    
        lsmod | grep `basename $1 | tr '-' '_'` > /dev/null || {
            DBG_PRINT ">>>> ${1}.ko not found in lsmod:"
            if grep "${1}.ko:" $_moddep > /dev/null; then
                echo "Error: $_moddep seems to be valid,"
                echo "       but `basename $1`.ko is not loaded."
                echo "       Please provide /proc/config.gz and ${KMODPATH}/*"
                echo "       for further investigation."
            else
                echo "Error: `basename $1`: $_moddep is invalid."
                echo "       Please run command 'depmod' on the target to re-generate it,"
                echo "       then reboot the target. If the issue still exists, please"
                echo "       ensure 'make module_install' is done properly."
            fi
    
            return 1
        }
        DBG_PRINT "${1}.ko done"
        return 0
    }
    
    # check kernel config, and modules (if CONFIG_*=M) for musb
    check_musb_drivers() {
        local _lst=("USB_MUSB_HDRC" "USB_MUSB_DUAL_ROLE" "USB_OTG" "USB_MUSB_DSPS" \
                    "AM335X_PHY_USB" "MUSB_PIO_ONLY" "TI_CPPI41")
        local _opts
    
        _opts=$(get_kernel_configs ${_lst[*]})
    
        check_kernel_config "$_opts" CONFIG_USB_MUSB_HDRC
        [ $? != 1 ] || check_module 'usb/musb/musb_hdrc'
    
        check_kernel_config "$_opts" CONFIG_USB_MUSB_DUAL_ROLE -q
        [ $? != 0 ] || echo "Warning: CONFIG_USB_MUSB_DUAL_ROLE undefined."
    
        check_kernel_config "$_opts" CONFIG_USB_OTG -q
        [ $? == 0 ] || echo "Warning: CONFIG_USB_OTG defined."
    
        check_kernel_config "$_opts" CONFIG_USB_MUSB_DSPS
        [ $? != 1 ] || {
            check_module 'usb/musb/musb_dsps'
        }
    
        check_kernel_config "$_opts" CONFIG_AM335X_PHY_USB
        [ $? != 1 ] || {
            check_module 'usb/phy/phy-am335x'
            check_module 'usb/phy/phy-am335x-control'
        }
    
        check_kernel_config "$_opts" CONFIG_MUSB_PIO_ONLY -q
        [ $? != 0 ] || {
           if check_kernel_config "$_opts" CONFIG_TI_CPPI41 -q; then
               echo "Error: MUSB CPPI DMA mode is enabled, but CPPI moudle is not enabled in DMA Engine."
               echo "       Please enable CONFIG_TI_CPPI41 under DMA Engine Support in kernel config."
           fi
        }
    }
    
    # check kernel config, and modules (if CONFIG_*=M) for dwc3
    check_dwc3_drivers() {
        local _lst=("USB_DWC3" "USB_DWC3_DUAL_ROLE" "USB_OTG" "USB_DWC3_OMAP" \
                    "USB_XHCI_HCD" "OMAP_CONTROL_PHY" "OMAP_USB2")
        local _opts
    
        _opts=$(get_kernel_configs ${_lst[*]})
    
        check_kernel_config "$_opts" CONFIG_USB_DWC3
        [ $? != 1 ] || check_module 'usb/dwc3/dwc3'
    
        check_kernel_config "$_opts" CONFIG_USB_DWC3_DUAL_ROLE -q
        [ $? != 0 ] || echo "Warning: CONFIG_USB_DWC3_DUAL_ROLE undefined."
    
        check_kernel_config "$_opts" CONFIG_USB_OTG -q
        [ $? == 0 ] || echo "Warning: CONFIG_USB_OTG defined."
    
        check_kernel_config "$_opts" CONFIG_USB_DWC3_OMAP
        [ $? != 1 ] || check_module 'usb/dwc3/dwc3-omap'
    
        check_kernel_config "$_opts" CONFIG_USB_XHCI_HCD
        [ $? != 1 ] || {
            check_module 'usb/host/xhci-plat-hcd'
            check_module 'usb/host/xhci-hcd'
        }
    
        check_kernel_config "$_opts" CONFIG_OMAP_CONTROL_PHY
        [ $? != 1 ] || check_module 'phy/ti/phy-omap-control'
    
        check_kernel_config "$_opts" CONFIG_OMAP_USB2
        [ $? != 1 ] || check_module 'phy/ti/phy-omap-usb2'
    }
    
    check_musb_dt() {
        local _dt_dir
        local _ent
        local _sts
        local _t
    
        case $USB_DT_PARENT in
            *"usb@"*)
                _ent=("control@44e10620" "usb-phy@47401300" "usb-phy@47401b00" \
                      "usb@47401000" "usb@47401800" "dma-controller@47402000")
                ;;
            *"target-module@"*)
                _ent=("usb-phy@1300" "usb-phy@1b00" "usb@1400" "usb@1800" \
                      "dma-controller@2000")
                ;;
            *)
                echo "Warning: unknown USB DT ($USB_DT_PARENT)"
                return
        esac
    
        echo "Device Tree USB node status:"
        for _t in '.' ${_ent[*]}; do
            [ -d "${USB_DT_PARENT}/${_t}/" ] || {
                echo -e "\tWarning: USB DT node $_t not found"
                continue
            }
            [ -f "${USB_DT_PARENT}/${_t}/status" ] &&
                _sts=$(tr -d '\0' <${USB_DT_PARENT}/${_t}/status) ||
                _sts="(enabled)"
            echo -e "\t$_t: $_sts"
        done
    }
    
    dump_sysfs_debugfs() {
        local _debugfs
        local _l
        local _f
    
        _debugfs=`sed -ne 's/^debugfs \(.*\) debugfs.*/\1/p' /proc/mounts`
        [ -n "$_debugfs" ] || return
    
        case $g_platform in
            am335x)
                _debugfs=$(find $_debugfs -name 'musb-hdrc.*')
                _debugfs=${_debugfs%/*}
    
                for _f in $USB0DEV $USB1DEV; do
                    _l=$(basename $_f)
                    echo "$_l: mode $(cat ${_f}/mode), $(cat ${_f}/vbus)"
                    grep -i 'power\|devctl\|testmode' ${_debugfs}/${_l}/regdump
                done
                ;;
        esac
    }
    
    check_gadget_kernel_config() {
        local _lst=("USB_ZERO" "USB_AUDIO" "USB_ETH" "USB_G_NCM" "USB_MASS_STORAGE" \
                    "USB_G_SERIAL" "USB_G_PRINTER")
        local _opts
    
        _opts=$(get_kernel_configs ${_lst[*]})
    
        check_kernel_config "$_opts" CONFIG_USB_ZERO -q ||
            echo "Gadget Kernel Config: g_zero is enabled"
        check_kernel_config "$_opts" CONFIG_USB_AUDIO -q ||
            echo "Gadget Kernel Config: g_audio is enabled"
        check_kernel_config "$_opts" CONFIG_USB_ETH -q ||
            echo "Gadget Kernel Config: g_ether is enabled"
        check_kernel_config "$_opts" CONFIG_USB_G_NCM -q ||
            echo "Gadget Kernel Config: g_ncm is enabled"
        check_kernel_config "$_opts" CONFIG_USB_MASS_STORAGE -q ||
            echo "Gadget Kernel Config: g_mass_storage is enabled"
        check_kernel_config "$_opts" CONFIG_USB_G_SERIAL -q ||
            echo "Gadget Kernel Config: g_serial is enabled"
        check_kernel_config "$_opts" CONFIG_USB_G_PRINTER -q ||
            echo "Gadget Kernel Config: g_printer is enabled"
    }
    
    ### debug ###
    
    g_log_file=/tmp/chkusb.log
    
    DBG_ENABLE() { g_dbg_enabled=true; }
    DBG_DISABLE() { g_dbg_enabled=false; }
    DBG_LOG_RESET() { ! $g_dbg_enabled || echo > $g_log_file; }
    DBG_PRINT() { ! $g_dbg_enabled || echo "$(date +%H:%M:%S) [$(basename $0)]: $*"; }
    DBG_LOG() { DBG_PRINT $* >> $g_log_file; }
    DBG_LOG_MARK() { DBG_PRINT "----------------" >> $g_log_file; }
    
    
    ### main ####
    
    g_printed_once=false
    
    echo "chkusb.sh Version $VERSION"
    
    [ "$V" = "1" ] && DBG_ENABLE && DBG_LOG_RESET || DBG_DISABLE
    
    has_supported_kernel ||
        { echo "Unsupported kernel version: `uname -r`"; exit 1; }
    check_platform || exit 2
    DBG_PRINT device: $g_platform
    [ -d ${DTPATH} ] || { echo "Error: ${DTPATH} not found"; exit 3; }
    
    check_command lsusb
    if lsusb > /dev/null 2>&1; then
        echo "USB is initialized"
    else
        echo "USB initialization failed"
    fi
    
    # check kernel configs
    
    if [ -f /proc/config.gz ]; then
        case $g_platform in
            am335x) check_musb_drivers;;
            am437x) check_dwc3_drivers;;
        esac
    else
        echo "Error: /proc/config.gz not found"
    fi
    
    dump_sysfs_debugfs
    
    # check dr_mode & gadget drivers
    
    check_command basename
    for _usb_dir in "${USB0DT}" "${USB1DT}"; do
        [ -n "$_usb_dir" ] || continue
    
        [ -f "$_usb_dir/status" ] &&
            _status=`tr -d '\0' <$_usb_dir/status` ||
            _status='(enabled)'
        _dr_mode=`tr -d '\0'  <$_usb_dir/dr_mode`
        echo `basename $_usb_dir`: $_dr_mode, $_status
    
        [ "$_status" = "disabled" -o "$_dr_mode" = "host" ] || gadget_mode=true
    done
    
    case $g_platform in
        am335x) check_musb_dt;;
        *) ;;
    esac
    
    DBG_PRINT $gadget_mode
    $gadget_mode || exit 0
    
    echo
    
    check_kernel_config "" CONFIG_USB_LIBCOMPOSITE
    case $? in
        0) echo "Error: no any gadget driver enabled"
           exit 6;;
        1) is_gadget_builtin=false;;
        2) echo "The gadget driver is built-in"
           is_gadget_builtin=true;;
    esac
    
    [[ ! -f /proc/config.gz ]] || check_gadget_kernel_config
    
    g_driver=`grep '^DRIVER=' /sys/class/udc/*/uevent 2>/dev/null`
    echo "gadget driver loaded: ${g_driver:-(none)}"
    
    [[ $is_gadget_builtin == false ]] || exit 0
    
    echo
    
    if [ -d "$KMODPATH" ]; then
        echo "The list of USB gadget drivers installed:"
        ls -1Rp ${KMODPATH}/kernel/drivers/usb/gadget/{function,legacy}/
    else
        echo "Error: $KMODPATH not found"
        echo "       Please ensure 'make modules_install' is done properly."
        exit 7
    fi
    
    # vim: ft=sh:ts=4:sw=4:et
    

  • Bin,

    Please help check the log, thanks.

    we can not say all 20pcs boards have this issue, but there are several boards happened, as did not make power cycle test to all boards.

    log20210416.txt
    chkusb.sh Version 0.3.2
    Linux am437x-evm 4.19.94-svn443 #182 PREEMPT Fri Apr 16 10:32:05 CST 2021 armv7l GNU/Linux
    USB initialization failed
    Error: /lib/modules/4.19.94-svn443/modules.dep seems to be valid,
           but dwc3.ko is not loaded.
           Please provide /proc/config.gz and /lib/modules/4.19.94-svn443/*
           for further investigation.
    Error: /lib/modules/4.19.94-svn443/modules.dep seems to be valid,
           but dwc3-omap.ko is not loaded.
           Please provide /proc/config.gz and /lib/modules/4.19.94-svn443/*
           for further investigation.
    Error: /lib/modules/4.19.94-svn443/modules.dep seems to be valid,
           but xhci-plat-hcd.ko is not loaded.
           Please provide /proc/config.gz and /lib/modules/4.19.94-svn443/*
           for further investigation.
    Error: /lib/modules/4.19.94-svn443/modules.dep seems to be valid,
           but xhci-hcd.ko is not loaded.
           Please provide /proc/config.gz and /lib/modules/4.19.94-svn443/*
           for further investigation.
    Error: /lib/modules/4.19.94-svn443/modules.dep seems to be valid,
           but phy-omap-usb2.ko is not loaded.
           Please provide /proc/config.gz and /lib/modules/4.19.94-svn443/*
           for further investigation.
    usb@48390000: host, okay
    usb@483d0000: host, okay
    
    Gadget Kernel Config: g_zero is enabled
    Gadget Kernel Config: g_audio is enabled
    Gadget Kernel Config: g_ether is enabled
    Gadget Kernel Config: g_ncm is enabled
    Gadget Kernel Config: g_mass_storage is enabled
    Gadget Kernel Config: g_serial is enabled
    Gadget Kernel Config: g_printer is enabled
    gadget driver loaded: (none)
    
    The list of USB gadget drivers installed:
    /lib/modules/4.19.94-svn443/kernel/drivers/usb/gadget/function/:
    u_audio.ko
    u_ether.ko
    u_serial.ko
    usb_f_acm.ko
    usb_f_ecm.ko
    usb_f_ecm_subset.ko
    usb_f_eem.ko
    usb_f_fs.ko
    usb_f_hid.ko
    usb_f_mass_storage.ko
    usb_f_midi.ko
    usb_f_ncm.ko
    usb_f_obex.ko
    usb_f_printer.ko
    usb_f_rndis.ko
    usb_f_serial.ko
    usb_f_ss_lb.ko
    usb_f_uac1.ko
    usb_f_uac1_legacy.ko
    usb_f_uac2.ko
    usb_f_uvc.ko
    
    /lib/modules/4.19.94-svn443/kernel/drivers/usb/gadget/legacy/:
    g_acm_ms.ko
    g_audio.ko
    g_cdc.ko
    g_dbgp.ko
    g_ether.ko
    g_ffs.ko
    g_hid.ko
    g_mass_storage.ko
    g_midi.ko
    g_multi.ko
    g_ncm.ko
    g_printer.ko
    g_serial.ko
    g_webcam.ko
    g_zero.ko
    gadgetfs.ko
    

  • Hi Tony,

    The usb drivers are not loaded. Please ask the customer to provide the file /proc/config.gz from the board.

    And please ask the customer to add some debug (using dev_info or dev_err) in function dwc3_omap_probe() in kernel file drivers/usb/dwc3/dwc3-omap.c to understand where the failure happens.