[BUG] FW reported error: 104 - Other failure of module instance initialization request

[keqiaozhang]

Describe the bug
Observed this issue in CI daily test, ipc error for msg 0x40000004|0x36 MOD_INIT_INSTANCE when testing suspend/resume with capture. The reproduce rate is low, tried 100+ iterations without errors.

dmesg

[ 2522.844245] kernel: snd_sof:sof_ipc4_widget_setup: sof-audio-pci-intel-tgl 0000:00:1f.3: Create widget alh-copier.SDW1-Capture.0 instance 0 - pipe 31 - core 0
[ 2522.844251] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc tx      : 0x40000004|0x36: MOD_INIT_INSTANCE [data size: 216]
[ 2522.844904] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc tx reply: 0x60000068|0x36: MOD_INIT_INSTANCE
[ 2522.844909] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: FW reported error: 104 - Other failure of module instance initialization request
[ 2522.844940] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc error for msg 0x40000004|0x36
[ 2522.844955] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: failed to create module alh-copier.SDW1-Capture.0
[ 2522.844969] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc tx      : 0x12000000|0x0: GLB_DELETE_PIPELINE
[ 2522.845393] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc tx reply: 0x32000000|0x0: GLB_DELETE_PIPELINE
[ 2522.845418] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-tgl 0000:00:1f.3: ipc tx done : 0x12000000|0x0: GLB_DELETE_PIPELINE
[ 2522.845429] kernel: snd_sof:sof_widget_free_unlocked: sof-audio-pci-intel-tgl 0000:00:1f.3: widget pipeline.31 freed
[ 2522.845434] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: Failed to set up connected widgets
[ 2522.845444] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: error: failed widget list set up for pcm 3 dir 1
[ 2522.845449] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: error: set pcm hw_params after resume
[ 2522.845453] kernel: sof-audio-pci-intel-tgl 0000:00:1f.3: ASoC: error at snd_soc_pcm_component_prepare on 0000:00:1f.3: -22
[ 2522.845458] kernel:  Amp feedback: ASoC: error at __soc_pcm_prepare on Amp feedback: -22
[ 2522.845464] kernel:  Amp feedback: ASoC: error at dpcm_fe_dai_prepare on Amp feedback: -22

mtrace

[    0.032523] <inf> main: main: SOF on intel_adsp_cavs25
[    0.032533] <inf> main: main: SOF initialized
[    0.032618] <inf> ipc: ipc_cmd: rx	: 0x44000000|0x31400008
[    0.032975] <inf> ipc: ipc_cmd: rx	: 0x44000000|0x3060004c
[    0.328450] <inf> ipc: ipc_cmd: rx	: 0x11000002|0x0
[    0.328476] <inf> pipe: pipeline_new: pipeline new pipe_id 0 priority 0
[    0.328893] <inf> ipc: ipc_cmd: rx	: 0x40000004|0x36
[    0.328985] <inf> dma: dma_get: dma_get() ID 0 sref = 1 busy channels 0
[    0.328998] <inf> ipc: dai_config: comp:0 0x40000 dai_config() dai type = 4 index = 513 dd 0x9e0b8f40
[    0.329091] <err> dai_comp: dai_common_new: comp:0 0x40000 dai_new(): dai_get() failed to create DAI.
[    0.329111] <err> copier: copier_dai_create: comp:0 0x40000 failed to create dai
[    0.329120] <err> copier: copier_new: unable to create dai
[    0.329146] <err> ipc: ipc4_init_module_instance: error: failed to init module 4 : 0
[    0.329156] <err> ipc: ipc_cmd: ipc4: MODULE_MSG failed with err 104
[    0.329591] <inf> ipc: ipc_cmd: rx	: 0x12000000|0xTerminated

To Reproduce
~/sof-test/test-case/check-suspend-resume-with-audio.sh -l 5 -m capture

Reproduction Rate
very low, hard to reproduce it manually.

Expected behavior

Environment

1. Branch name and commit hash of the 2 repositories: sof (firmware/topology) and linux (kernel driver).
   • Kernel: {34b7f81747f8}
   • SOF: {7458312a7655}
2. Name of the topology file
   • Topology: {avs-tplg/sof-adl-rt711-l0-rt1316-l12-rt714-l3.tplg}
3. Name of the platform(s) on which the bug is observed.
   • Platform: {ADLP_SKU0B00_SDCA_IPC4ZPH}

[keqiaozhang]

No reproductions in CI for a month. Closing this bug.