This post has just crossed with yours:
I've used both a DFRobot DFplayer Mini and a pure SD card reader in my tests recently. The test I gave you to try was actually for a pure SD card reader.
My suggestion is this:
- Format the SD card again (quick format)
- Create 1 new folder on the SD card called mp3
- Rename BGSOUND.MP3 in windows to 0001.mp3
- copy 0001.mp3 to the folder mp3 on the SD card.
So, on the SD card you now have 1 folder called mp3 containing one file called 0001.mp3 and try with that.
Maybe use the example code here and modify as required: Arduino Application - Test DFPlayer Mini MP3 Module - DFRobot
Are you using the Windows encrypting file system on your PC ? If you do, copied encrypted fiels won't work on the player.
I did find this DFPlayer_Mini_mp3/DFPlayer Mini Manual.pdf at master · Arduinolibrary/DFPlayer_Mini_mp3 · GitHub where note 6 at the end talks vaguely of 3.3 volt pins. A Uno is 5volt.