Orin-Nano: l4t_initrd_flash.sh: how to create a smaller image like demo-image?

Issue Overview

Users are experiencing difficulties when attempting to flash a smaller image onto storage devices less than 64GB for the Nvidia Jetson Orin Nano Developer Kit. The specific symptoms include errors indicating that the GPT (GUID Partition Table) is larger than the device storage. This issue arises during the flashing process using the l4t_initrd_flash.sh script, particularly when trying to create a flashable system.img that fits onto a 32GB SD card. Users have noted that while they can successfully flash a demo image of 22GB onto a 32GB SD card, attempts to resize the system.img.raw using the -S <size>GiB option still result in errors related to partition size. The issue appears to be consistent across multiple users, impacting their ability to utilize the Jetson Orin Nano effectively.

Possible Causes

1. Hardware Incompatibilities: The SD card or other storage devices may not be fully compatible with the flashing process, leading to errors.
2. Software Bugs: There may be bugs in the l4t_initrd_flash.sh script or related tools that fail to handle resizing correctly.
3. Configuration Errors: Incorrect settings in configuration files, such as flash_l4t_external.xml, may lead to improper sector calculations.
4. Driver Issues: Outdated or incompatible drivers could affect the flashing process and lead to errors.
5. Environmental Factors: Power supply issues or temperature extremes might impact device performance during flashing.
6. User Errors: Misconfigurations by users during the flashing process may contribute to the problem.

Troubleshooting Steps, Solutions & Fixes

1. Modify Configuration File:

   • Navigate to Linux_for_Tegra/tools/kernel_flash/flash_l4t_external.xml.
   • Adjust the num_sectors entry according to your SD card size. For example, for a 32GB SD card:

     <device type="external" instance="0" sector_size="512" num_sectors="62914560">
     

   • This value is calculated as $$ \text{GB} \times 1024 \times 1024 / 512 $$.

2. Use Correct Flash Command:

   • When executing the flash command, ensure you specify a size that fits your SD card:

     sudo ./tools/kernel_flash/l4t_initrd_flash.sh --external-device mmcblk1p1 -S 20GiB -c tools/kernel_flash/flash_l4t_external.xml -p "-c bootloader/t186ref/cfg/flash_t234_qspi.xml" --showlogs --network usb0 jetson-orin-nano-devkit internal
     

3. Pre-formatting SD Card:

   • Format the SD card as a single ext4 partition before attempting to flash again.

4. Testing Different Sizes:

   • Users have reported success with different sizes; try using -S 20GiB, -S 25GiB, or even smaller sizes if necessary.

5. Check for Missing Files:

   • Ensure that all required files are present, particularly flash.idx, which appears missing in some error logs.

6. Use SDK Manager for Flashing:

   • If issues persist, consider using NVIDIA’s SDK Manager for flashing instead of manual methods, as it may handle dependencies and configurations better.

7. Monitor UART Logs:

   • Check UART logs for additional error messages that could provide insight into what might be going wrong during the flashing process.

8. Community Resources:

   • Engage with community forums and documentation for additional troubleshooting tips and user experiences.

9. Best Practices:

   • Always ensure that your power supply meets the requirements (e.g., 19V for Orin Nano).
   • Keep your firmware and software up-to-date with the latest versions from NVIDIA.

By following these steps and recommendations, users should be able to troubleshoot and resolve issues related to flashing smaller images onto their Jetson Orin Nano Developer Kit effectively.