Hi Rich,
Do you mean by normal play to play for example a playlist instead of looping one file?
I think the bug is directly related to one process opening the ALSA device and continuously playing sound to it for a long time. Closing the old process and starting a new one seems to restart this 6 hour time, as well as keeping the process open but stopping writes to the ALSA PCM device for several seconds and then resuming them.
I've currently solved it in my application by restarting the python script every 6 hours, but it seems like a hack rather than a real fix, especially as this problem only happens with USB sound cards, + restarting the script produces an audible gap in playback. I'm planning to use an I2S DAC now to have better reliability, but it's still interesting to know what is causing this problem.
max_usb_current=1
Thanks for the suggestion, but I'm afraid this didn't help, the sound crashed again.