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[BUG] "IPC timed out" on multiple ACE platforms with xrun warnings in mtrace #9914

@lyakh

Description

@lyakh

Describe the bug
multiple-pause-resume-50 and multiple-pipeline-playback tests fail on PTL and LNL with xrun floods in mtrace logs, leading to IPC timeouts.

Example 1:
https://sof-ci.01.org/linuxpr/PR5369/build6689/devicetest/index.html?model=PTLP_RVP_SDW&testcase=multiple-pipeline-all
platform: PTL
test: multiple-pipeline-all
mtrace:

[00:00:05.803,305] <inf> ipc: ipc_cmd: rx	: 0x12020000|0x0
[00:00:05.803,328] <inf> dma: sof_dma_put: dma_put(), dma = 0x4009e2e0, sref = 2
[00:00:05.803,335] <inf> dai_intel_dmic: dai_dmic_remove: dmic_remove(), dmic_active_fifos_mask = 0x0, dmic_pause_mask = 0x0
[00:00:05.803,443] <inf> host_comp: host_get_copy_bytes_normal: comp:5 0x70002 no bytes to copy, available samples: 0, free_samples: 384
[00:00:05.804,441] <inf> host_comp: host_get_copy_bytes_normal: comp:5 0x70002 no bytes to copy, available samples: 0, free_samples: 384
[00:00:05.805,441] <inf> host_comp: host_get_copy_bytes_normal: comp:5 0x70002 no bytes to copy, available samples: 0, free_samples: 384

Linux kernel:

[ 1605.125092] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-ptl 0000:00:1f.3: ipc tx      : 0x12020000|0x0: GLB_DELETE_PIPELINE
[ 1605.125189] kernel: snd_sof:sof_pcm_trigger: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm1 (Jack In), dir 1: Entry: trigger (cmd: 0)
[ 1605.125194] kernel: snd_sof:sof_ipc4_trigger_pipelines: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm1 (Jack In), dir 1: cmd: 0, state: 3
[ 1605.125476] kernel: soundwire_bus:sdw_slave_get_scale_index: rt722-sdca sdw:0:3:025d:0722:01: Configured bus base 1, scale 3, mclk 19200000, curr_freq 4800000
[ 1605.129152] kernel: snd_sof:sof_pcm_trigger: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm4 (Microphone), dir 1: Entry: trigger (cmd: 0)
[ 1605.129159] kernel: snd_sof:sof_ipc4_trigger_pipelines: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm4 (Microphone), dir 1: cmd: 0, state: 3
[ 1605.135919] kernel: snd_sof:sof_pcm_trigger: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm0 (Jack Out), dir 0: Entry: trigger (cmd: 0)
[ 1605.135937] kernel: snd_sof:sof_ipc4_trigger_pipelines: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm0 (Jack Out), dir 0: cmd: 0, state: 3
[ 1605.136063] kernel: snd_sof:sof_pcm_trigger: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm31 (Deepbuffer Jack Out), dir 0: Entry: trigger (cmd: 0)
[ 1605.136069] kernel: snd_sof:sof_ipc4_trigger_pipelines: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm31 (Deepbuffer Jack Out), dir 0: cmd: 0, state: 3
[ 1605.136094] kernel: snd_sof:sof_pcm_trigger: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm2 (Speaker), dir 0: Entry: trigger (cmd: 0)
[ 1605.136100] kernel: snd_sof:sof_ipc4_trigger_pipelines: sof-audio-pci-intel-ptl 0000:00:1f.3: pcm2 (Speaker), dir 0: cmd: 0, state: 3
[ 1605.625967] kernel: sof-audio-pci-intel-ptl 0000:00:1f.3: ipc timed out for 0x12020000|0x0

Example 2:
https://sof-ci.01.org/sofpr/PR9860/build11121/devicetest/index.html?model=LNLM_RVP_HDA&testcase=multiple-pause-resume-50
platform: LNL
test: multiple-pause-resume-50
mtrace:

[  763.205285] \<inf\> host_comp: host_get_copy_bytes_normal: comp:3 0x40004 no bytes to copy, available samples: 0, free_samples: 768

Linux kernel:

[  762.318154] kernel: snd_sof:sof_ipc4_log_header: sof-audio-pci-intel-lnl 0000:00:1f.3: ipc tx      : 0x12010000|0x0: GLB_DELETE_PIPELINE
[  762.824476] kernel: sof-audio-pci-intel-lnl 0000:00:1f.3: ipc timed out for 0x12010000|0x0

Example 3 (uncertain):
platform: LNL
test: multiple-pause-resume-50
mtrace:

[ 1439.250870] <wrn> dai_comp: dai_common_copy: comp:0 0x4 nothing to copy, src_frames: 0, sink_frames: 96

Linux kernel:
(none)
Uncertain because the firmware flooding error is different, configuration is different (SDW vs. HDA), no kernel logs to check IPC timeouts

To Reproduce
So far observed with multiple-pause-resume-50 and multiple-pipeline-playback tests on LNL and PTL platforms in HDA configurations

Reproduction Rate
Rare

Impact
Must be fixed

Environment
The oldest of the above examples is from Feb 26 2025

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