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ARM RL-FlashFS native SD Card corruption ffree()

Hi,
Wonder if anyone could help me. I’ve got an SD card related problem.
My project builds under uVisionV4.73.0.0, C Compiler Armcc.Exe V5.03.0.76, device = STM32F427II.
My target platform has a native SD card device (2GB capacity and FAT file structure) for which we’re using Keil’s RL-FLashFS i.e. SDIO_STM32F4xx.c , File_Config,c (Rev V4.70). My target platform is a custom hardware design.

The problem
The SD card becomes corrupt however I can still read and write files to it from my target platform perfectly well and finit() returns 0 indicating the card is in good working order however:

- ffree() takes over 1 second to complete whereas normally it completes in approximately 70mSec on a card that hasn’t been corrupted (this very slow response prevents my target booting which is how I discovered the card corruption).

- My Windows PC reports 700+ MB of used space on the card when the files on the card add up to less than 10 MB.

- Windows CHKDSK reports the SD card has errors and can repair it; it finds around 24,000 x 32KB bad clusters. Once CHKDSK has repaired the card the used space equates roughly to the size of the files on the card and ffree() calls on my target platform complete in the usual 70mSec time period.

BTW when I make a copy of the corrupted card using HDDGuru’s HDDRawCopy1.10 the copy has the same 700+MB of wasted (corrupted) space just like the original but when I insert the card into my target platform calls to ffree() complete in the normal 70mSec time frame?

Specifically I would help with
1. Detecting the SD card corruption in my target platform, everything appears to work fine apart from the very slow ffree(); unfortunately fanalyse() and fcheck() aren’t available to me because it is a FAT file system.
2. Understanding why a low level copy of the card doesn’t suffer from the very slow ffree() response.
3. Ultimately stopping the corruption from occurring in the first place.

Many thanks in advance for any assistance/advice you can give me.

Paul

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