add CONFIG_BT_ENABLED to sdkconfig.h for proper BT RF calibration; patch NimBLEDevice.cpp to skip controller init if already done by Arduino framework

pre_build.py

@@ -70,9 +70,8 @@ def patch_sdkconfig_bt():
         content = f.read()
 
     defines = {
-        # Do NOT set CONFIG_BT_ENABLED here — that forces the Arduino
-        # framework to pre-init the BT controller at startup, which
-        # conflicts with USB. NimBLEDevice::init() handles its own init.
+        "CONFIG_BT_ENABLED": 1,
+        "CONFIG_BT_NIMBLE_ENABLED": 1,
         "CONFIG_BTDM_CTRL_MODE_BLE_ONLY": 1,
         "CONFIG_BT_NIMBLE_MAX_CONNECTIONS": 1,
         "CONFIG_BT_NIMBLE_TASK_STACK_SIZE": 6144,
@@ -161,6 +160,95 @@ def patch_nimconfig():
     print("nimconfig.h patched successfully")
 
 
+def patch_nimble_device():
+    # Find NimBLEDevice.cpp in the NimBLE-Arduino library
+    search_dirs = [
+        os.path.join(os.getcwd(), ".pio", "libdeps"),
+        os.path.expanduser("~/.platformio/lib"),
+    ]
+    for env_dir in ["esp32s3", ""]:
+        candidate = os.path.join(
+            os.getcwd(), ".pio", "libdeps",
+            env_dir, "NimBLE-Arduino", "src", "NimBLEDevice.cpp"
+        ) if env_dir else ""
+        if candidate and os.path.exists(candidate):
+            dev_path = candidate
+            break
+    else:
+        dev_path = None
+        for base in search_dirs:
+            if not os.path.exists(base):
+                continue
+            for root, _dirs, files in os.walk(base):
+                if "NimBLEDevice.cpp" in files:
+                    dev_path = os.path.join(root, "NimBLEDevice.cpp")
+                    break
+            if dev_path:
+                break
+
+    if not dev_path:
+        print("WARNING: NimBLEDevice.cpp not found, skipping controller init patch")
+        return
+
+    print(f"Patching {dev_path} to handle double BT controller init")
+
+    with open(dev_path, 'r') as f:
+        content = f.read()
+
+    # Replace the ESP_ERROR_CHECK(esp_bt_controller_init) block to handle
+    # ESP_ERR_INVALID_STATE (already initialized by Arduino framework when CONFIG_BT_ENABLED)
+    old_block = (
+        '        ESP_ERROR_CHECK(esp_bt_controller_init(&bt_cfg));\n'
+        '        ESP_ERROR_CHECK(esp_bt_controller_enable(ESP_BT_MODE_BLE));\n'
+        '        ESP_ERROR_CHECK(esp_nimble_hci_init());'
+    )
+    new_block = (
+        '        if (esp_bt_controller_init(&bt_cfg) == ESP_OK) {\n'
+        '            ESP_ERROR_CHECK(esp_bt_controller_enable(ESP_BT_MODE_BLE));\n'
+        '        }\n'
+        '        ESP_ERROR_CHECK(esp_nimble_hci_init());'
+    )
+
+    if old_block in content:
+        content = content.replace(old_block, new_block)
+        with open(dev_path, 'w') as f:
+            f.write(content)
+        print("  Patched esp_bt_controller_init to skip if already initialized")
+    else:
+        # Try alternative indentation (1 tab = 8 spaces)
+        old_block_alt = old_block.replace('        ', '\t')
+        new_block_alt = new_block.replace('        ', '\t')
+        if old_block_alt in content:
+            content = content.replace(old_block_alt, new_block_alt)
+            with open(dev_path, 'w') as f:
+                f.write(content)
+            print("  Patched (tab-indented) esp_bt_controller_init")
+        else:
+            # Try with partial indentation
+            patterns = [
+                (r'(\s*)ESP_ERROR_CHECK\(esp_bt_controller_init\(&bt_cfg\)\);\s*\n'
+                 r'\1ESP_ERROR_CHECK\(esp_bt_controller_enable\(ESP_BT_MODE_BLE\)\);\s*\n'
+                 r'\1ESP_ERROR_CHECK\(esp_nimble_hci_init\(\)\);'),
+            ]
+            for pattern in patterns:
+                replacement = (
+                    r'\1if (esp_bt_controller_init(&bt_cfg) == ESP_OK) {\n'
+                    r'\1    ESP_ERROR_CHECK(esp_bt_controller_enable(ESP_BT_MODE_BLE));\n'
+                    r'\1}\n'
+                    r'\1ESP_ERROR_CHECK(esp_nimble_hci_init());'
+                )
+                new_content = re.sub(pattern, replacement, content)
+                if new_content != content:
+                    content = new_content
+                    with open(dev_path, 'w') as f:
+                        f.write(content)
+                    print("  Patched esp_bt_controller_init (regex)")
+                    break
+            else:
+                print("  WARNING: Could not find esp_bt_controller_init pattern in NimBLEDevice.cpp")
+
+
 patch_usb_ids()
 patch_sdkconfig_bt()
-patch_nimconfig()
+patch_nimconfig()
+patch_nimble_device()