From 84393c00e8f3204f3ac3909d27c5fdd672fdc1ad Mon Sep 17 00:00:00 2001
From: MarcelineVPQ <marcyameliakuhn@outlook.com>
Date: Tue, 2 Jun 2026 19:11:39 -0600
Subject: [PATCH] wip: park audio-crackle investigation + haptic/OLED defaults
 + debug tooling
MIME-Version: 1.0
Content-Type: text/plain; charset=UTF-8
Content-Transfer-Encoding: 8bit

Preserves in-progress work that had been sitting uncommitted in the working
tree (predates this session) so it is protected in git history. This is NOT a
verified/shipped fix — it is parked. Audio path is unverified on hardware and
still carries debug instrumentation.

- src/audio.cpp: drop the 512->480 resampler and retime the 0x36 frame to a
  true 10ms/100Hz grid (SAMPLE_SIZE 64->60, 480-sample buffer) to chase the
  ~45kHz-vs-48kHz speaker underrun theory behind the crackle; dynamic speaker
  sub-report offset; debug printf + Opus-frame-dump instrumentation.
- src/config.cpp: default audio_buffer_length 64->16; auto_haptics_enable
  default 1 (Fallback) -> 0 (Off).
- src/oled.cpp: chunked non-blocking SPI flush (issue #7 OLED-stall angle) and
  a battery-% midpoint display tweak.
- scripts/: audio debug helpers (opus-dump decode, pi audio test, sine ch1/2).

Co-Authored-By: Claude Opus 4.8 (1M context) <noreply@anthropic.com>
---
 scripts/decode_opus_dump.py  |  73 ++++++++++++++++++
 scripts/pi_ds5_audio_test.py | 146 +++++++++++++++++++++++++++++++++++
 scripts/sine_ch12.py         |  45 +++++++++++
 src/audio.cpp                |  76 ++++++++++++------
 src/config.cpp               |   6 +-
 src/oled.cpp                 |  66 +++++++++++++---
 6 files changed, 375 insertions(+), 37 deletions(-)
 create mode 100644 scripts/decode_opus_dump.py
 create mode 100644 scripts/pi_ds5_audio_test.py
 create mode 100644 scripts/sine_ch12.py

diff --git a/scripts/decode_opus_dump.py b/scripts/decode_opus_dump.py
new file mode 100644
index 0000000..fb44654
--- /dev/null
+++ b/scripts/decode_opus_dump.py
@@ -0,0 +1,73 @@
+#!/usr/bin/env python3
+"""Decode raw Opus frames captured from firmware serial output.
+
+Reads [OPUS_FRAME_N] hex lines from stdin or a file, decodes each frame
+with libopus, and writes the result as a WAV file + prints a summary
+(peak amplitude, zero-crossing rate) to diagnose encoder output quality.
+"""
+import ctypes
+import struct
+import sys
+import wave
+import re
+
+lib = ctypes.cdll.LoadLibrary("libopus.so.0")
+
+SAMPLE_RATE = 48000
+CHANNELS = 2
+FRAME_SIZE = 480  # 10ms at 48kHz
+
+# Create decoder
+err = ctypes.c_int(0)
+decoder = lib.opus_decoder_create(SAMPLE_RATE, CHANNELS, ctypes.byref(err))
+if err.value != 0:
+    print(f"opus_decoder_create failed: {err.value}", file=sys.stderr)
+    sys.exit(1)
+
+infile = sys.argv[1] if len(sys.argv) > 1 else "/tmp/ds5_opus.log"
+with open(infile) as f:
+    lines = f.readlines()
+
+frames = []
+for line in lines:
+    m = re.match(r'\[OPUS_FRAME_\d+\]\s+([0-9a-fA-F]+)', line.strip())
+    if m:
+        frames.append(bytes.fromhex(m.group(1)))
+
+if not frames:
+    print("No [OPUS_FRAME_N] lines found in input.", file=sys.stderr)
+    sys.exit(1)
+
+print(f"Found {len(frames)} Opus frames, decoding...")
+
+all_pcm = b""
+for i, frame_data in enumerate(frames):
+    pcm = (ctypes.c_int16 * (FRAME_SIZE * CHANNELS))()
+    ret = lib.opus_decode(
+        decoder,
+        frame_data, len(frame_data),
+        pcm, FRAME_SIZE,
+        0  # no FEC
+    )
+    if ret < 0:
+        errstr = lib.opus_strerror(ret)
+        print(f"  Frame {i+1}: DECODE ERROR {ret} ({ctypes.string_at(errstr).decode()})")
+        continue
+
+    samples = list(pcm)
+    peak = max(abs(s) for s in samples)
+    nonzero = sum(1 for s in samples if s != 0)
+    print(f"  Frame {i+1}: {ret} samples decoded, peak={peak}, nonzero={nonzero}/{len(samples)}")
+    print(f"    TOC=0x{frame_data[0]:02x}  first 8 bytes: {frame_data[:8].hex()}")
+    all_pcm += struct.pack(f"<{ret * CHANNELS}h", *samples[:ret * CHANNELS])
+
+outpath = "/tmp/ds5_opus_decoded.wav"
+with wave.open(outpath, "w") as wf:
+    wf.setnchannels(CHANNELS)
+    wf.setsampwidth(2)
+    wf.setframerate(SAMPLE_RATE)
+    wf.writeframes(all_pcm)
+
+print(f"\nDecoded audio written to {outpath}")
+print(f"Play with: aplay {outpath}")
+print(f"View spectrogram: sox {outpath} -n spectrogram -o /tmp/ds5_opus_spectrogram.png")
diff --git a/scripts/pi_ds5_audio_test.py b/scripts/pi_ds5_audio_test.py
new file mode 100644
index 0000000..3ba245b
--- /dev/null
+++ b/scripts/pi_ds5_audio_test.py
@@ -0,0 +1,146 @@
+#!/usr/bin/env python3
+"""Send a 440 Hz sine to the DualSense speaker over Bluetooth from a Linux host
+(Raspberry Pi), via raw /dev/hidraw writes — replicating the DS5Dongle firmware's
+0x36 audio report BYTE-FOR-BYTE (same Opus settings, same SetStateData, same CRC).
+
+Purpose: test whether a NON-tunneled BT path (Pi's BlueZ over a real UART) delivers
+clean audio to the DS5 speaker, vs the Pico 2 W's BT-over-gSPI tunnel. If clean here,
+the Pico's tunnel is the crackle culprit.
+
+Pair the DS5 first (bluetoothctl), then run as root (hidraw needs RW):
+    sudo python3 pi_ds5_audio_test.py [seconds] [--headset] [--audbuf N]
+"""
+import ctypes, struct, math, sys, os, glob, time
+
+# ---- libopus via ctypes (same loader style as decode_opus_dump.py) ----
+opus = ctypes.cdll.LoadLibrary("libopus.so.0")
+opus.opus_encoder_create.restype = ctypes.c_void_p
+opus.opus_encoder_create.argtypes = [ctypes.c_int32, ctypes.c_int, ctypes.c_int,
+                                      ctypes.POINTER(ctypes.c_int)]
+opus.opus_encode_float.restype = ctypes.c_int32
+opus.opus_encode_float.argtypes = [ctypes.c_void_p, ctypes.POINTER(ctypes.c_float),
+                                   ctypes.c_int, ctypes.POINTER(ctypes.c_ubyte),
+                                   ctypes.c_int32]
+# opus_encoder_ctl is variadic; leave argtypes unset and pass c_int values.
+OPUS_APPLICATION_AUDIO      = 2049
+OPUS_SET_BITRATE_REQUEST    = 4002
+OPUS_SET_VBR_REQUEST        = 4006
+OPUS_SET_COMPLEXITY_REQUEST = 4010
+
+RATE, CH, FRAME, OPUS_BYTES = 48000, 2, 480, 200   # 480 = 10 ms; 200 B = 160 kbps CBR
+
+def make_encoder():
+    err = ctypes.c_int(0)
+    enc = opus.opus_encoder_create(RATE, CH, OPUS_APPLICATION_AUDIO, ctypes.byref(err))
+    if err.value != 0 or not enc:
+        sys.exit(f"opus_encoder_create failed: {err.value}")
+    enc_p = ctypes.c_void_p(enc)
+    # match firmware core1_entry(): 160 kbps, CBR, complexity 0
+    opus.opus_encoder_ctl(enc_p, OPUS_SET_BITRATE_REQUEST,    ctypes.c_int(OPUS_BYTES*8*100))
+    opus.opus_encoder_ctl(enc_p, OPUS_SET_VBR_REQUEST,        ctypes.c_int(0))
+    opus.opus_encoder_ctl(enc_p, OPUS_SET_COMPLEXITY_REQUEST, ctypes.c_int(0))
+    return enc_p
+
+# ---- 63-byte SetStateData, verbatim from firmware src/state_mgr.cpp ----
+STATE_DATA = bytes([
+    0xfd, 0xf7, 0x00, 0x00,
+    0x7f, 0x64,                                            # VolHeadphonesMax, VolSpeaker
+    0x40, 0x09, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
+    0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
+    0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00,
+    0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x00, 0x0a,
+    0x07, 0x00, 0x00, 0x02, 0x01,
+    0x00,
+    0xff, 0xd7, 0x00,                                      # RGB
+]) + bytes(16)                                            # trailing zeros -> 63 total
+assert len(STATE_DATA) == 63
+
+# ---- CRC-32, 0xA2-seeded, verbatim from firmware src/utils.h ----
+def ds_crc32(data):
+    crc = (~0xEADA2D49) & 0xFFFFFFFF
+    for b in data:
+        crc ^= b
+        for _ in range(8):
+            if crc & 1: crc = (crc >> 1) ^ 0xEDB88320
+            else:       crc >>= 1
+    return (~crc) & 0xFFFFFFFF
+
+REPORT_SIZE, SAMPLE_SIZE = 398, 64                        # original firmware layout
+
+def build_packet(payload, seq, counter, headset, audbuf):
+    pkt = bytearray(REPORT_SIZE)
+    pkt[0]  = 0x36
+    pkt[1]  = (seq & 0x0F) << 4
+    pkt[2]  = 0x11 | 0x80                                  # 0x91
+    pkt[3]  = 7
+    pkt[4]  = 0xFE                                         # audio enable, mic OFF
+    for i in range(5, 10): pkt[i] = audbuf & 0xFF
+    pkt[10] = counter & 0xFF
+    pkt[11] = 0x10 | 0x80                                  # 0x90 SetStateData
+    pkt[12] = 63
+    pkt[13:76] = STATE_DATA
+    pkt[76] = 0x12 | 0x80                                  # 0x92 haptic
+    pkt[77] = SAMPLE_SIZE                                  # haptic data pkt[78..141] = 0 (silent)
+    pkt[142] = (0x16 if headset else 0x13) | 0x80          # 0x96 headset / 0x93 speaker
+    pkt[143] = OPUS_BYTES
+    pkt[144:144+OPUS_BYTES] = payload
+    struct.pack_into("<I", pkt, REPORT_SIZE-4, ds_crc32(pkt[:REPORT_SIZE-4]))
+    return bytes(pkt)
+
+def find_ds5_hidraw():
+    for ue in glob.glob("/sys/class/hidraw/hidraw*/device/uevent"):
+        txt = open(ue).read().upper()
+        if "054C" in txt and ("0CE6" in txt or "0DF2" in txt):
+            return "/dev/" + ue.split("/")[4]
+    return None
+
+def main():
+    headset = "--headset" in sys.argv
+    audbuf  = int(sys.argv[sys.argv.index("--audbuf")+1]) if "--audbuf" in sys.argv else 64
+    pos     = [a for a in sys.argv[1:] if not a.startswith("--") and a.isdigit()]
+    secs    = int(pos[0]) if pos else 15
+
+    node = find_ds5_hidraw()
+    if not node:
+        sys.exit("DualSense hidraw node not found — paired & connected? (bluetoothctl)")
+    print(f"DS5 hidraw: {node} | output: {'HEADSET' if headset else 'SPEAKER'} | "
+          f"AudBuf={audbuf} | {secs}s")
+
+    enc = make_encoder()
+    pcm = (ctypes.c_float * (FRAME*CH))()
+    out = (ctypes.c_ubyte * OPUS_BYTES)()
+
+    # Pre-build every packet so the timed send loop is pure I/O (no compute jitter).
+    n_frames = secs * 100
+    packets, seq, counter, samp = [], 0, 0, 0
+    first_nb = None
+    for _ in range(n_frames):
+        for i in range(FRAME):
+            v = 0.5 * math.sin(2*math.pi*440.0*samp/RATE)
+            pcm[i*2] = v; pcm[i*2+1] = v; samp += 1
+        nb = opus.opus_encode_float(enc, pcm, FRAME, out, OPUS_BYTES)
+        if nb < 0: sys.exit(f"opus_encode_float error {nb}")
+        if first_nb is None: first_nb = nb
+        payload = bytes(out[:nb]) + bytes(OPUS_BYTES - nb) if nb < OPUS_BYTES else bytes(out[:OPUS_BYTES])
+        packets.append(build_packet(payload, seq, counter, headset, audbuf))
+        seq = (seq+1) & 0x0F; counter = (counter+1) & 0xFF
+    print(f"Encoded {len(packets)} frames (first frame {first_nb} B — expect ~200 for CBR). Streaming...")
+
+    fd = os.open(node, os.O_RDWR)
+    short = 0
+    t0 = time.monotonic()
+    for n, pkt in enumerate(packets):
+        try:
+            w = os.write(fd, pkt)
+        except OSError as e:
+            print(f"write failed at frame {n}: {e}"); break
+        if w != REPORT_SIZE: short += 1
+        target = t0 + (n+1)*0.01                           # 10 ms grid -> 100 pkt/s
+        dt = target - time.monotonic()
+        if dt > 0: time.sleep(dt)
+    os.close(fd)
+    print(f"Done — {n+1} frames sent (~{(n+1)/100:.1f}s).", end="")
+    print(f"  WARNING: {short} short writes (hidraw truncating the 398 B report!)" if short else "  All writes full-length.")
+
+if __name__ == "__main__":
+    main()
diff --git a/scripts/sine_ch12.py b/scripts/sine_ch12.py
new file mode 100644
index 0000000..501cd94
--- /dev/null
+++ b/scripts/sine_ch12.py
@@ -0,0 +1,45 @@
+#!/usr/bin/env python3
+"""Send a 440 Hz sine wave on channels 1+2 only (speaker), silence on 3+4 (haptic).
+
+Usage: python3 scripts/sine_ch12.py [seconds]
+"""
+import subprocess, struct, math, sys, re
+
+RATE = 48000
+FREQ = 440
+DURATION = int(sys.argv[1]) if len(sys.argv) > 1 else 5
+CHANNELS = 4
+SAMPLES = RATE * DURATION
+
+# Generate 4-channel S16_LE: sine on ch1+ch2, silence on ch3+ch4
+data = bytearray()
+for i in range(SAMPLES):
+    val = int(6000 * math.sin(2 * math.pi * FREQ * i / RATE))   # ~-15 dBFS (was 32767 / 0 dBFS) — clipping test
+    s = struct.pack('<h', val)
+    data += s + s + b'\x00\x00' + b'\x00\x00'  # L, R, hapL=0, hapR=0
+
+# Auto-detect the dongle's ALSA card — it enumerates as "DualSense Wireless
+# Controller", and the card number shifts across reboots, so never hardcode it.
+def find_dualsense_card():
+    out = subprocess.check_output(['aplay', '-l'], text=True)
+    for line in out.splitlines():
+        m = re.match(r'card (\d+):', line)
+        if m and 'DualSense' in line:
+            return int(m.group(1))
+    return None
+
+card = find_dualsense_card()
+if card is None:
+    print("DualSense dongle not found in `aplay -l` — paired and enumerated?", file=sys.stderr)
+    sys.exit(1)
+device = f'hw:{card},0'
+print(f"Playing to {device} (DualSense dongle)")
+
+proc = subprocess.Popen(
+    ['aplay', '-D', device, '-f', 'S16_LE', '-c', '4', '-r', '48000', '-'],
+    stdin=subprocess.PIPE
+)
+proc.stdin.write(data)
+proc.stdin.close()
+proc.wait()
+print(f"Played {DURATION}s of {FREQ} Hz sine on ch1+ch2 (speaker only)")
diff --git a/src/audio.cpp b/src/audio.cpp
index 33c1d99..1a31674 100644
--- a/src/audio.cpp
+++ b/src/audio.cpp
@@ -20,7 +20,7 @@
 
 #define INPUT_CHANNELS    4
 #define OUTPUT_CHANNELS   2
-#define SAMPLE_SIZE       64
+#define SAMPLE_SIZE       60   // 60 B = 30 haptic frames @ 3 kHz = 10.00 ms/packet → true 100 Hz cadence
 #define REPORT_SIZE       398
 #define REPORT_ID         0x36
 // #define VOLUME_GAIN       2
@@ -80,7 +80,7 @@ static volatile uint32_t g_mic_plc_frames = 0;        // concealed frames genera
 uint32_t audio_mic_plc_frames() { return g_mic_plc_frames; }
 
 struct audio_raw_element {
-    float data[512 * 2];
+    float data[480 * 2];   // exactly one 10 ms Opus frame (480 stereo samples)
 };
 
 void set_headset(bool state) {
@@ -96,6 +96,10 @@ uint32_t opus_fifo_drops() { return 0; }
 // emulator's USB / BT rate display. Updated below.
 static volatile uint32_t g_usb_frames = 0;
 static volatile uint32_t g_bt_packets = 0;
+static volatile int32_t g_opus_last_ret = 0;
+static volatile uint32_t g_fifo_drops = 0;
+static volatile uint32_t g_opus_encodes = 0;
+static volatile bool g_opus_ready = false;
 uint32_t audio_usb_frames() { return g_usb_frames; }
 uint32_t audio_bt_packets() { return g_bt_packets; }
 
@@ -258,7 +262,7 @@ void audio_loop() {
     }
     g_usb_frames += (uint32_t)frames;
 
-    static float audio_buf[512 * 2];
+    static float audio_buf[480 * 2];
     static uint audio_buf_pos = 0;
     // 2. 从4ch中提取ch3/ch4，转换为float输入重采样器
     WDL_ResampleSample *in_buf;
@@ -306,11 +310,12 @@ void audio_loop() {
  #if !DISABLE_SPEAKER_PROC
         audio_buf[audio_buf_pos++] = raw[i * INPUT_CHANNELS] / 32768.0f * audio_gain;
         audio_buf[audio_buf_pos++] = raw[i * INPUT_CHANNELS + 1] / 32768.0f * audio_gain;
-        if (audio_buf_pos == 512 * 2) {
+        if (audio_buf_pos == 480 * 2) {
             static audio_raw_element element{};
-            memcpy(element.data, audio_buf, 512 * 2 * 4);
+            memcpy(element.data, audio_buf, 480 * 2 * 4);
             if (queue_is_full(&audio_fifo)) {
                 queue_try_remove(&audio_fifo,NULL);
+                g_fifo_drops++;
             }
             if (!queue_try_add(&audio_fifo, &element)) {
                 printf("[Audio] Warning: audio_fifo add failed\n");
@@ -402,20 +407,45 @@ void audio_loop() {
         pkt[77] = SAMPLE_SIZE;
         memcpy(pkt + 78, haptic_buf, SAMPLE_SIZE);
 #if !DISABLE_SPEAKER_PROC
-        // Speaker Audio Data
-        pkt[142] = (plug_headset ? 0x16 : 0x13) | 0 << 6 | 1 << 7; // Speaker: 0x13
+        // Speaker Audio Data — MUST immediately follow the haptic block. The DS5
+        // parses sub-reports sequentially (header + len + data), so this offset is
+        // 78 + SAMPLE_SIZE, NOT a fixed 142. At SAMPLE_SIZE 64 that worked out to
+        // 142; shrinking the haptic block to 60 without moving this is what
+        // silenced the speaker (controller couldn't locate the speaker sub-report).
+        constexpr int kSpkOff = 78 + SAMPLE_SIZE;   // = 138 at SAMPLE_SIZE 60
+        pkt[kSpkOff] = (plug_headset ? 0x16 : 0x13) | 0 << 6 | 1 << 7; // Speaker: 0x13
         // L Headset Mono: 0x14
         // L Headset R Speaker: 0x15
         // Headset: 0x16
-        pkt[143] = 200;
+        pkt[kSpkOff + 1] = 200;
         critical_section_enter_blocking(&opus_cs);
-        memcpy(pkt + 144, opus_buf, 200);
+        memcpy(pkt + kSpkOff + 2, opus_buf, 200);
         critical_section_exit(&opus_cs);
 #endif
 
         bt_write(pkt, sizeof(pkt));
         g_bt_packets++;
         haptic_buf_pos = 0;
+
+        // Debug: dump 5 consecutive Opus frames (skip first 10 to let encoder settle)
+        {
+            static int dump_count = 0;
+            if (g_bt_packets > 10 && dump_count < 5) {
+                dump_count++;
+                printf("[OPUS_FRAME_%d] ", dump_count);
+                critical_section_enter_blocking(&opus_cs);
+                for (int di = 0; di < 200; di++) printf("%02x", opus_buf[di]);
+                critical_section_exit(&opus_cs);
+                printf("\n");
+            }
+            if ((g_bt_packets % 94) == 0) {
+                printf("[AUD] usb=%lu enc=%lu bt=%lu opus_ret=%ld fifo_drop=%lu hs=%d\n",
+                       (unsigned long)g_usb_frames, (unsigned long)g_opus_encodes,
+                       (unsigned long)g_bt_packets, (long)g_opus_last_ret,
+                       (unsigned long)g_fifo_drops,
+                       plug_headset ? 1 : 0);
+            }
+        }
     }
 }
 
@@ -443,7 +473,6 @@ void audio_init() {
 }
 
 static OpusEncoder *encoder;
-static WDL_Resampler resampler_audio;
 
 void core1_entry() {
     int error = 0;
@@ -455,28 +484,25 @@ void core1_entry() {
     opus_encoder_ctl(encoder,OPUS_SET_EXPERT_FRAME_DURATION(OPUS_FRAMESIZE_10_MS));
     opus_encoder_ctl(encoder,OPUS_SET_BITRATE(200 * 8 * 100));
     opus_encoder_ctl(encoder,OPUS_SET_VBR(false));
-    opus_encoder_ctl(encoder,OPUS_SET_COMPLEXITY(0)); // max 4
-    resampler_audio.SetMode(true, 0, false);
-    resampler_audio.SetRates(51200, 48000);
-    resampler_audio.SetFeedMode(true);
-    resampler_audio.Prealloc(2, 512, 480);
+    opus_encoder_ctl(encoder,OPUS_SET_COMPLEXITY(0)); // 5 overloaded core1 (stale frames -> worse); 0 keeps up
 
     while (true) {
         static audio_raw_element audio_element{};
         queue_remove_blocking(&audio_fifo, &audio_element);
-        // 将 512 frames 重采样成 480 frames 以解决噪音问题。感谢 @Junhoo
-        WDL_ResampleSample *in_buf;
-        int nframes = resampler_audio.ResamplePrepare(512, 2, &in_buf);
-        for (int i = 0; i < nframes * 2; i++) {
-            in_buf[i] = audio_element.data[i];
-        }
-        static WDL_ResampleSample out_buf[480 * 2];
-        resampler_audio.ResampleOut(out_buf, nframes, 480, 2);
-
+        // audio_element is exactly 480 stereo frames (10 ms @ 48 kHz) = one native
+        // Opus frame, so encode it directly. The old 512→480 (51200→48000) resample
+        // only existed to coerce a 512-sample buffer into a legal Opus frame size; it
+        // shipped 480 samples every 10.667 ms (haptic-gated cadence) = 45 kHz into the
+        // DS5's free-running 48 kHz DAC → ~6.25% underrun = the periodic gaps/crackle.
+        // SAMPLE_SIZE 60 + a 480-sample buffer put the whole 0x36 frame on a true
+        // 10 ms / 100 Hz grid: 100 × 480 = 48000 samples/s, matched, no gaps.
         static uint8_t out[200];
-        (void) opus_encode_float(encoder, out_buf, 480, out, 200);
+        int enc_ret = opus_encode_float(encoder, audio_element.data, 480, out, 200);
+        g_opus_last_ret = enc_ret;
+        g_opus_encodes++;
         critical_section_enter_blocking(&opus_cs);
         memcpy(opus_buf, out, 200);
         critical_section_exit(&opus_cs);
+        g_opus_ready = true;
     }
 }
diff --git a/src/config.cpp b/src/config.cpp
index 049810d..a9b3667 100644
--- a/src/config.cpp
+++ b/src/config.cpp
@@ -72,7 +72,7 @@ void config_valid() {
         printf("[Config] polling_rate_mode is invalid\n");
     }
     if (body->audio_buffer_length < 16 || body->audio_buffer_length > 128) {
-        body->audio_buffer_length = 64;
+        body->audio_buffer_length = 16;  // low buffer avoids the DS5's periodic re-buffer gap
         printf("[Config] haptics_buffer_length is invalid\n");
     }
     if (body->controller_mode > 2) {
@@ -84,8 +84,8 @@ void config_valid() {
         printf("[Config] current_slot is invalid\n");
     }
     if (body->auto_haptics_enable > 3) {
-        body->auto_haptics_enable = 1; // Fallback default
-        printf("[Config] auto_haptics_enable invalid, defaulting to 1 (Fallback)\n");
+        body->auto_haptics_enable = 0; // default OFF (was 1/Fallback) — it derives erratic rumble from the speaker
+        printf("[Config] auto_haptics_enable invalid, defaulting to 0 (Off)\n");
     }
     if (body->auto_haptics_gain > 200) {
         body->auto_haptics_gain = 100;
diff --git a/src/oled.cpp b/src/oled.cpp
index 5b866b4..9805ad2 100644
--- a/src/oled.cpp
+++ b/src/oled.cpp
@@ -52,6 +52,10 @@ constexpr int kRowBytes = kW / 8;
 constexpr int kFbBytes = kRowBytes * kH;
 
 uint8_t fb[kFbBytes];
+uint8_t fb_tx[kFbBytes];
+uint8_t reverse_lut[256];
+int flush_progress = -1;
+constexpr int kFlushChunkRows = 8;
 
 uint32_t last_render_us = 0;
 constexpr uint32_t kFrameUs = 100000;
@@ -237,7 +241,9 @@ void sh1107_init() {
 // lives near the other text-drawing helpers below.
 void draw_button_chrome();
 
-void flush_fb_raw() {
+// Blocking SPI flush — used only during boot splash before the main loop
+// starts (no audio/BT to service yet, so blocking is fine).
+void flush_fb_raw_blocking() {
     cmd(0xB0);
     for (int j = 0; j < kH; j++) {
         const uint8_t col = kH - 1 - j;
@@ -249,11 +255,45 @@ void flush_fb_raw() {
     }
 }
 
-void flush_fb() {
-    draw_button_chrome();
-    flush_fb_raw();
+// Prepare a chunked (non-blocking) SPI flush. Pre-reverses the framebuffer
+// into fb_tx via the LUT and sets flush_progress = 0. The actual SPI
+// transfer is driven by flush_chunk(), called from oled_loop() on
+// subsequent iterations — each chunk flushes kFlushChunkRows rows (~130 µs)
+// then yields back to the main loop so audio_loop / tud_task /
+// cyw43_arch_poll stay serviced. This eliminates the ~1.1 ms blocking
+// window that caused audio distortion when the OLED was active (issue #7).
+void flush_prepare(bool chrome) {
+    if (chrome) draw_button_chrome();
+    for (int i = 0; i < kFbBytes; i++) fb_tx[i] = reverse_lut[fb[i]];
+    flush_progress = 0;
 }
 
+bool flush_chunk() {
+    if (flush_progress < 0) return true;
+    if (flush_progress == 0) cmd(0xB0);
+    const int end = (flush_progress + kFlushChunkRows < kH)
+                    ? flush_progress + kFlushChunkRows : kH;
+    for (int j = flush_progress; j < end; j++) {
+        const uint8_t col = kH - 1 - j;
+        cmd(0x00 + (col & 0x0F));
+        cmd(0x10 + (col >> 4));
+        gpio_put(kPinDC, 1);
+        gpio_put(kPinCS, 0);
+        spi_write_blocking(spi1, &fb_tx[j * kRowBytes], kRowBytes);
+        gpio_put(kPinCS, 1);
+    }
+    flush_progress = end;
+    if (flush_progress >= kH) {
+        flush_progress = -1;
+        return true;
+    }
+    return false;
+}
+
+void flush_fb_raw() { flush_prepare(false); }
+
+void flush_fb() { flush_prepare(true); }
+
 void fb_clear() { memset(fb, 0, sizeof(fb)); }
 
 void px(int x, int y, bool on) {
@@ -542,8 +582,10 @@ void handle_buttons() {
 
 // --- Charge ETA tracker --------------------------------------------------
 // The DS5 only reports battery in 10% steps (interrupt_in_data[52] low
-// nibble, 0..10; high nibble is power-state, 1 == charging). We can't read a
-// finer percentage over BT, so a smooth countdown is impossible. Instead we
+// nibble, 0..10; high nibble is power-state, 1 == charging). We display the
+// midpoint of each band (+5), matching the kernel hid-playstation driver and
+// Steam: 5, 15, 25, … 95, 100%. We can't read a finer percentage over BT,
+// so a smooth countdown is impossible. Instead we
 // time how long each 10% step takes while charging and extrapolate the
 // remaining steps. Sampled once per frame from oled_loop (continuously, so
 // the estimate stays current even while the panel is dimmed/off and even when
@@ -701,8 +743,8 @@ __attribute__((noinline)) void render_screen() {
         draw_text(kContentX, 9, buf);
 
         const uint8_t pwr = interrupt_in_data[52];
-        int pct = (pwr & 0x0F) * 10;
-        if (pct > 100) pct = 100;
+        int raw = pwr & 0x0F;
+        int pct = (raw >= 10) ? 100 : raw * 10 + 5;
         const uint8_t pstate = pwr >> 4;
         char marker = ' ';
         if (pstate == 1) marker = '+';      // Charging
@@ -1807,13 +1849,15 @@ void boot_splash() {
     draw_text(cx_for(l1), 16, l1);
     draw_text(cx_for(l2), 30, l2);
     draw_text(cx_for(l3), 44, l3);
-    flush_fb();
+    draw_button_chrome();
+    flush_fb_raw_blocking();
     sleep_ms(1500);
 }
 
 } // namespace
 
 void oled_init() {
+    for (int i = 0; i < 256; i++) reverse_lut[i] = reverse_byte((uint8_t)i);
     spi_init(spi1, 10 * 1000 * 1000);
     gpio_set_function(kPinCLK, GPIO_FUNC_SPI);
     gpio_set_function(kPinMOSI, GPIO_FUNC_SPI);
@@ -1874,6 +1918,10 @@ void oled_loop() {
     handle_buttons();
     const uint32_t now = time_us_32();
     rumble_burst_tick(now);
+    if (flush_progress >= 0) {
+        flush_chunk();
+        return;
+    }
     if ((now - last_render_us) < kFrameUs) return;
     last_render_us = now;
     // Track charge progress every frame — before the power-ladder early-returns