feat: enhance OTA update process with improved file verification and new OTA data initialization

.github/workflows/providers/gitea-release.yml

@@ -46,27 +46,56 @@ jobs:
     - name: Build Firmware
       run: |
         source venv/bin/activate
+        # Ensure clean build
+        platformio run -t clean
+        
         echo "Building SPIFFS..."
         platformio run -t buildfs
         
         echo "Building firmware..."
         platformio run
+        
+        # Get esp32 bootloader
+        python -c "import pkg_resources; print(pkg_resources.resource_filename('platformio', 'packages/framework-arduinoespressif32/tools/sdk/esp32/bin/bootloader_dio_40m.bin'))" > bootloader_path.txt
+        cp $(cat bootloader_path.txt) .pio/build/esp32dev/bootloader.bin
 
     - name: Create Release Files
       run: |
         source venv/bin/activate
-        echo "Creating release files..."
+        
+        # Verify file existence and sizes
+        echo "Verifying build files..."
+        ls -lh .pio/build/esp32dev/bootloader.bin
+        ls -lh .pio/build/esp32dev/partitions.bin
+        ls -lh .pio/build/esp32dev/firmware.bin
+        ls -lh .pio/build/esp32dev/spiffs.bin
+        ls -lh .pio/build/esp32dev/ota_data_initial.bin
+        
+        # Create OTA file (firmware only)
+        echo "Creating OTA update binary..."
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman_ota.bin
+        
+        # Create full flash binary
+        echo "Creating full binary..."
         esptool.py --chip esp32 merge_bin \
+          -o .pio/build/esp32dev/filaman_full.bin \
           --flash_mode dio \
           --flash_freq 40m \
           --flash_size 4MB \
-          -o .pio/build/esp32dev/filaman_full.bin \
+          0x0000 .pio/build/esp32dev/bootloader.bin \
-          0x1000 .pio/build/esp32dev/bootloader.bin \
           0x8000 .pio/build/esp32dev/partitions.bin \
+          0xe000 .pio/build/esp32dev/ota_data_initial.bin \
           0x10000 .pio/build/esp32dev/firmware.bin \
           0x3D0000 .pio/build/esp32dev/spiffs.bin
         
-        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman_ota.bin
+        # Verify created files and show sizes
+        echo "Verifying created files..."
+        ls -lh .pio/build/esp32dev/filaman_full.bin
+        ls -lh .pio/build/esp32dev/filaman_ota.bin
+        
+        # Show binary info
+        echo "Binary information:"
+        esptool.py --chip esp32 image_info .pio/build/esp32dev/filaman_full.bin
 
     - name: Read CHANGELOG.md
       id: changelog

platformio.ini

@@ -65,6 +65,7 @@ build_flags =
     -DCONFIG_BOOTLOADER_RESERVE_RTC_SIZE=0x1000
     -DCONFIG_PARTITION_TABLE_OFFSET=0x8000
     -DCONFIG_PARTITION_TABLE_MD5=y
+    -DBOOT_APP_PARTITION_OTA_0=1
     
 extra_scripts = 
     scripts/extra_script.py
@@ -72,6 +73,7 @@ extra_scripts =
     pre:scripts/pre_spiffs.py    ; wird als zweites ausgeführt
     pre:scripts/combine_html.py  ; wird als drittes ausgeführt
     scripts/gzip_files.py
+    post:post_extra_script.py
 
 ; Remove or comment out the targets line
 ;targets = buildfs, build

scripts/post_extra_script.py

@@ -0,0 +1,22 @@
+Import("env")
+import os
+
+def create_ota_data_initial(source, target, env):
+    build_dir = env.subst("$BUILD_DIR")
+    ota_data_path = os.path.join(build_dir, "ota_data_initial.bin")
+    
+    # WLED-style OTA data initialization
+    # First 32 bytes are for the first OTA slot
+    # Next 32 bytes are for the second OTA slot
+    # Pattern: 0x00 for the running partition, 0x55 for others
+    ota_data = bytearray([0x00] * 32 + [0x55] * 32)
+    
+    # Fill the rest with 0xFF
+    ota_data.extend([0xFF] * (0x2000 - len(ota_data)))
+    
+    with open(ota_data_path, 'wb') as f:
+        f.write(ota_data)
+    
+    print(f"Created ota_data_initial.bin ({len(ota_data)} bytes)")
+
+env.AddPostAction("$BUILD_DIR/${PROGNAME}.bin", create_ota_data_initial)

src/ota.cpp

@@ -22,23 +22,47 @@ void stopAllTasks() {
 }
 
 void handleOTAUpload(AsyncWebServerRequest *request, String filename, size_t index, uint8_t *data, size_t len, bool final) {
+    static size_t contentLength = 0;
+    static bool isFullImage = false;
+    
     if (!index) {
-        Serial.printf("Update Start: %s\n", filename.c_str());
+        contentLength = request->contentLength();
-        if (request->contentLength() == 0) {
+        Serial.printf("Update Start: %s (size: %u bytes)\n", filename.c_str(), contentLength);
+        
+        if (contentLength == 0) {
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid file size\"}");
             return;
         }
 
+        // Bei full.bin muss das Magic Byte nicht geprüft werden
+        isFullImage = (contentLength > 0x300000);
+        if (!isFullImage && data[0] != ESP_MAGIC) {
+            Serial.printf("Wrong magic byte: 0x%02X (expected 0x%02X)\n", data[0], ESP_MAGIC);
+            request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid firmware format\"}");
+            return;
+        }
+
         if (!tasksAreStopped && (RfidReaderTask || BambuMqttTask || ScaleTask)) {
             stopAllTasks();
             tasksAreStopped = true;
         }
 
-        if (!Update.begin(UPDATE_SIZE_UNKNOWN)) {
+        if (!Update.begin(contentLength, isFullImage ? U_FLASH : U_FLASH)) {
             Update.printError(Serial);
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"OTA could not begin\"}");
             return;
         }
+        
+        Serial.printf("Starting %s update\n", isFullImage ? "full" : "firmware");
+    }
+
+    // Debug output für die ersten paar Bytes
+    if (index == 0) {
+        Serial.printf("First bytes: ");
+        for(size_t i = 0; i < min(16UL, len); i++) {
+            Serial.printf("%02X ", data[i]);
+        }
+        Serial.println();
     }
 
     if (Update.write(data, len) != len) {
@@ -53,6 +77,7 @@ void handleOTAUpload(AsyncWebServerRequest *request, String filename, size_t ind
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"OTA end failed\"}");
             return;
         }
+        Serial.println("Update successful, restarting...");
         request->send(200, "application/json", "{\"status\":\"success\",\"message\":\"Update successful! Device will restart...\",\"restart\":true}");
         delay(500);
         ESP.restart();