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WL1835MOD: wlcore: ERROR command complete timeout kernel BUG at startup

Part Number: WL1835MOD

Tool/software:

Some field units are experiencing this issue which prevents disassociation.

After several firmware restarts, as you can see below, it appears to stabilize and associate with the AP.  However, it is negatively affecting customer experiences.  Any advice would be much appreciated.

[    6.303486] wl18xx_driver wl18xx.0.auto: Direct firmware load for ti-connectivity/wl1271-nvs.bin failed with error -2
[    6.822676] wlcore: wl18xx HW: 183x or 180x, PG 2.2 (ROM 0x11)
[    6.837628] wlcore: loaded
[    7.104155] EXT4-fs: Warning: mounting with data=journal disables delayed allocation and O_DIRECT support!
[   25.080401] wlcore: PHY firmware version: Rev 8.2.0.0.246
[   25.175284] wlcore: firmware booted (Rev 8.9.0.0.90)
[   25.189383] IPv6: ADDRCONF(NETDEV_UP): wlan0: link is not ready
[   27.381815] wlcore: ERROR command complete timeout
[   27.381830] ------------[ cut here ]------------
[   27.381984] WARNING: CPU: 0 PID: 275 at drivers/net/wireless/ti/wlcore/main.c:807 wl12xx_queue_recovery_work+0x2c/0x60 [wlcore]
[   27.381991] Modules linked in: wl18xx wlcore sensedaq_driver(O) wlcore_sdio sense_multicolor_led(O)
[   27.382021] CPU: 0 PID: 275 Comm: wpa_supplicant Tainted: G           O      4.19.325-cip116-rt40 #7
[   27.382025] Hardware name: Generic AM33XX (Flattened Device Tree)
[   27.382060] [<c010d798>] (unwind_backtrace) from [<c010b4f8>] (show_stack+0x10/0x14)
[   27.382085] [<c010b4f8>] (show_stack) from [<c0125fcc>] (__warn+0xc0/0xd4)
[   27.382108] [<c0125fcc>] (__warn) from [<c07429c4>] (warn_slowpath_null+0x38/0x48)
[   27.382173] [<c07429c4>] (warn_slowpath_null) from [<bf028c54>] (wl12xx_queue_recovery_work+0x2c/0x60 [wlcore])
[   27.382279] [<bf028c54>] (wl12xx_queue_recovery_work [wlcore]) from [<bf02b790>] (wlcore_cmd_send_failsafe+0x94/0x48c [wlcore])
[   27.382377] [<bf02b790>] (wlcore_cmd_send_failsafe [wlcore]) from [<bf02bba0>] (wl1271_cmd_send+0x18/0x24 [wlcore])
[   27.382475] [<bf02bba0>] (wl1271_cmd_send [wlcore]) from [<bf02d0d4>] (wl1271_cmd_template_set+0xd4/0x114 [wlcore])
[   27.382574] [<bf02d0d4>] (wl1271_cmd_template_set [wlcore]) from [<bf02d224>] (wl12xx_cmd_build_probe_req+0x110/0x14c [wlcore])
[   27.382703] [<bf02d224>] (wl12xx_cmd_build_probe_req [wlcore]) from [<bf05e8bc>] (wl18xx_scan_start+0x1a0/0x260 [wl18xx])
[   27.382795] [<bf05e8bc>] (wl18xx_scan_start [wl18xx]) from [<bf03a13c>] (wlcore_scan+0xc8/0xdc [wlcore])
[   27.382897] [<bf03a13c>] (wlcore_scan [wlcore]) from [<bf0240a8>] (wl1271_op_hw_scan+0xf0/0x120 [wlcore])
[   27.382957] [<bf0240a8>] (wl1271_op_hw_scan [wlcore]) from [<c06e1434>] (__ieee80211_start_scan+0x770/0x808)
[   27.382972] [<c06e1434>] (__ieee80211_start_scan) from [<c06e1fdc>] (ieee80211_request_scan+0x28/0x40)
[   27.382997] [<c06e1fdc>] (ieee80211_request_scan) from [<c06b3d4c>] (nl80211_trigger_scan+0x4d4/0x6bc)
[   27.383014] [<c06b3d4c>] (nl80211_trigger_scan) from [<c055fb80>] (genl_rcv_msg+0x2fc/0x37c)
[   27.383027] [<c055fb80>] (genl_rcv_msg) from [<c055e824>] (netlink_rcv_skb+0xa4/0x10c)
[   27.383037] [<c055e824>] (netlink_rcv_skb) from [<c055f2f0>] (genl_rcv+0x20/0x34)
[   27.383048] [<c055f2f0>] (genl_rcv) from [<c055e030>] (netlink_unicast+0x14c/0x20c)
[   27.383058] [<c055e030>] (netlink_unicast) from [<c055e4cc>] (netlink_sendmsg+0x34c/0x37c)
[   27.383071] [<c055e4cc>] (netlink_sendmsg) from [<c050c198>] (__sock_sendmsg+0x14/0x24)
[   27.383082] [<c050c198>] (__sock_sendmsg) from [<c050c734>] (___sys_sendmsg+0x1dc/0x22c)
[   27.383094] [<c050c734>] (___sys_sendmsg) from [<c050d63c>] (__sys_sendmsg+0x50/0x94)
[   27.383106] [<c050d63c>] (__sys_sendmsg) from [<c0101000>] (ret_fast_syscall+0x0/0x5c)
[   27.383113] Exception stack(0xdab5bfa8 to 0xdab5bff0)
[   27.383124] bfa0:                   00000000 bea30a70 00000006 bea30a70 00000000 00000001
[   27.383135] bfc0: 00000000 bea30a70 00000006 00000128 00000004 bea30af0 00000001 00000000
[   27.383143] bfe0: 00000128 bea30a30 b6c87bc5 b6c12536
[   27.383150] ---[ end trace 0000000000000002 ]---
[   27.383178] wlcore: WARNING cmd set_template failed: -110
[   27.383195] wlcore: ERROR 2.4GHz PROBE request template failed
[   29.051418] sched: RT throttling activated
[   29.051472] wlcore: Hardware recovery in progress. FW ver: Rev 8.9.0.0.90
[   29.102217] wlcore: pc: 0x115616, hint_sts: 0x00000200 count: 1
[   29.102573] wlcore: down
[   29.131916] ieee80211 phy0: Hardware restart was requested
[   29.812218] wlcore: PHY firmware version: Rev 8.2.0.0.246
[   29.875396] wlcore: firmware booted (Rev 8.9.0.0.90)
[   30.718403] wlan0: authenticate with fc:ec:da:a4:d3:58
[   30.762027] wlcore: ERROR SW watchdog interrupt received! starting recovery.
[   30.762043] ------------[ cut here ]------------
[   30.762198] WARNING: CPU: 0 PID: 177 at drivers/net/wireless/ti/wlcore/main.c:807 wl12xx_queue_recovery_work+0x2c/0x60 [wlcore]
[   30.762205] Modules linked in: wl18xx wlcore sensedaq_driver(O) wlcore_sdio sense_multicolor_led(O)
[   30.762235] CPU: 0 PID: 177 Comm: irq/50-wl18xx Tainted: G        W  O      4.19.325-cip116-rt40 #7
[   30.762239] Hardware name: Generic AM33XX (Flattened Device Tree)
[   30.762275] [<c010d798>] (unwind_backtrace) from [<c010b4f8>] (show_stack+0x10/0x14)
[   30.762300] [<c010b4f8>] (show_stack) from [<c0125fcc>] (__warn+0xc0/0xd4)
[   30.762324] [<c0125fcc>] (__warn) from [<c07429c4>] (warn_slowpath_null+0x38/0x48)
[   30.762392] [<c07429c4>] (warn_slowpath_null) from [<bf028c54>] (wl12xx_queue_recovery_work+0x2c/0x60 [wlcore])
[   30.762494] [<bf028c54>] (wl12xx_queue_recovery_work [wlcore]) from [<bf029398>] (wlcore_irq+0xf8/0x170 [wlcore])
[   30.762550] [<bf029398>] (wlcore_irq [wlcore]) from [<c0162190>] (irq_thread_fn+0x1c/0x58)
[   30.762562] [<c0162190>] (irq_thread_fn) from [<c0162404>] (irq_thread+0xdc/0x200)
[   30.762579] [<c0162404>] (irq_thread) from [<c01427e0>] (kthread+0x164/0x17c)
[   30.762594] [<c01427e0>] (kthread) from [<c01010f0>] (ret_from_fork+0x14/0x24)
[   30.762600] Exception stack(0xda20ffb0 to 0xda20fff8)
[   30.762609] ffa0:                                     00000000 00000000 00000000 00000000
[   30.762619] ffc0: 00000000 00000000 00000000 00000000 00000000 00000000 00000000 00000000
[   30.762628] ffe0: 00000000 00000000 00000000 00000000 00000013 00000000
[   30.762634] ---[ end trace 0000000000000003 ]---
[   30.762746] wlcore: Hardware recovery in progress. FW ver: Rev 8.9.0.0.90
[   30.763457] wlcore: pc: 0x115616, hint_sts: 0x00000000 count: 2
[   30.763835] wlcore: down
[   30.764016] ieee80211 phy0: Hardware restart was requested
[   30.774427] systemd-journald[136]: Data hash table of /run/log/journal/7c0f5db1e50445ce8b212b67dbbdd37e/system.journal has a fill level at 75.0 (1536 of 2047 items, 1048576 file size, 682 bytes per hash table item), suggesting rotation.
[   30.774478] systemd-journald[136]: /run/log/journal/7c0f5db1e50445ce8b212b67dbbdd37e/system.journal: Journal header limits reached or header out-of-date, rotating.
[   30.791794] wlan0: failed to insert STA entry for the AP (error -16)
[   31.358537] wlcore: PHY firmware version: Rev 8.2.0.0.246
[   31.435461] wlcore: firmware booted (Rev 8.9.0.0.90)