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

@@ -48,28 +48,30 @@ jobs:
       run: |
         cd .pio/build/esp32dev
         
-        # Kopiere die Firmware in den SPIFFS-Build-Ordner
+        # Create OTA binary (already has correct magic byte)
-        cp firmware.bin ./spiffs/firmware.bin
+        cp firmware.bin filaman.bin
         
-        # Baue das SPIFFS-Image neu mit der eingebetteten Firmware
+        # Create a magic byte prepended binary for the bootloader
-        pio run -t buildfs
+        echo -ne '\xE9' > bootloader_with_magic.bin
+        cat bootloader.bin >> bootloader_with_magic.bin
         
-        # Erstelle die Release-Dateien
+        echo "Creating full binary with magic byte..."
-        cp spiffs.bin filaman_spiffs.bin
-        
-        # Create full binary with magic byte
-        echo "Creating full binary..."
         esptool.py --chip esp32 merge_bin \
           --fill-flash-size 4MB \
           --flash_mode dio \
           --flash_freq 40m \
           --flash_size 4MB \
-          -o filaman_full.bin \
+          -o filaman.bin \
-          0x0000 bootloader.bin \
+          0x0000 bootloader_with_magic.bin \
           0x8000 partitions.bin \
           0x10000 firmware.bin \
           0x390000 spiffs.bin
         
+        # Verify magic bytes
+        echo "Checking magic bytes:"
+        echo "Full binary first bytes:"
+        xxd -l 16 filaman.bin
+        
         # Verify file sizes
         echo "File sizes:"
         ls -lh *.bin
@@ -101,7 +103,7 @@ jobs:
           
           # Upload binaries
           cd .pio/build/esp32dev
-          for file in filaman_ota.bin filaman_spiffs.bin filaman_full.bin; do
+          for file in filaman.bin; do
             echo "Uploading $file..."
             curl -k -s \
               -X POST \

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

@@ -37,28 +37,30 @@ jobs:
       run: |
         cd .pio/build/esp32dev
         
-        # Kopiere die Firmware in den SPIFFS-Build-Ordner
+        # Create OTA binary (already has correct magic byte)
-        cp firmware.bin ./spiffs/firmware.bin
+        cp firmware.bin filaman.bin
         
-        # Baue das SPIFFS-Image neu mit der eingebetteten Firmware
+        # Create a magic byte prepended binary for the bootloader
-        pio run -t buildfs
+        echo -ne '\xE9' > bootloader_with_magic.bin
+        cat bootloader.bin >> bootloader_with_magic.bin
         
-        # Erstelle die Release-Dateien
+        echo "Creating full binary with magic byte..."
-        cp spiffs.bin filaman_spiffs.bin
-        
-        # Create full binary with magic byte
-        echo "Creating full binary..."
         esptool.py --chip esp32 merge_bin \
           --fill-flash-size 4MB \
           --flash_mode dio \
           --flash_freq 40m \
           --flash_size 4MB \
-          -o filaman_full.bin \
+          -o filaman.bin \
-          0x0000 bootloader.bin \
+          0x0000 bootloader_with_magic.bin \
           0x8000 partitions.bin \
           0x10000 firmware.bin \
           0x390000 spiffs.bin
         
+        # Verify magic bytes
+        echo "Checking magic bytes:"
+        echo "Full binary first bytes:"
+        xxd -l 16 filaman.bin
+        
         # Verify file sizes
         echo "File sizes:"
         ls -lh *.bin
@@ -84,4 +86,4 @@ jobs:
         gh release create "${{ github.ref_name }}" \
           --title "Release ${{ steps.get_version.outputs.VERSION }}" \
           --notes "${{ steps.changelog.outputs.CHANGES }}" \
-          .pio/build/esp32dev/filaman_full.bin
+          .pio/build/esp32dev/filaman.bin

CHANGELOG.md

@@ -1,11 +1,5 @@
 # Changelog
 
-## [1.2.89] - 2025-02-20
-### Changed
-- update webpages for version v1.2.89
-- enhance OTA update process with SPIFFS support and improved error handling
-
-
 ## [1.2.88] - 2025-02-20
 ### Changed
 - update webpages for version v1.2.88

html/header.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/index.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/rfid.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/spoolman.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/upgrade.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/waage.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

html/wifi.html

@@ -12,7 +12,7 @@
         <div style="display: flex; align-items: center; gap: 2rem;">
             <img src="/logo.png" alt="FilaMan Logo" class="logo">
             <div class="logo-text">
-                <h1>FilaMan<span class="version">v1.2.89</span></h1>
+                <h1>FilaMan<span class="version">v1.2.88</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

platformio.ini

@@ -9,7 +9,7 @@
 ; https://docs.platformio.org/page/projectconf.html
 
 [common]
-version = "1.2.89"
+version = "1.2.88"
 
 [env:esp32dev]
 platform = espressif32

src/ota.cpp

@@ -20,150 +20,81 @@ void stopAllTasks() {
     Serial.println("All tasks stopped");
 }
 
-void performStageTwo() {
-    if (!SPIFFS.begin(true)) {
-        Serial.println("Error: Could not mount SPIFFS for stage 2");
-        return;
-    }
-
-    File firmwareFile = SPIFFS.open("/firmware.bin", "r");
-    if (!firmwareFile) {
-        Serial.println("Error: Could not open firmware.bin from SPIFFS");
-        return;
-    }
-
-    size_t firmwareSize = firmwareFile.size();
-    size_t maxAppSpace = (ESP.getFreeSketchSpace() - 0x1000) & 0xFFFFF000;
-
-    Serial.printf("Stage 2 - Firmware size: %u bytes\n", firmwareSize);
-    Serial.printf("Available space: %u bytes\n", maxAppSpace);
-
-    if (firmwareSize > maxAppSpace) {
-        Serial.printf("Error: Not enough space for firmware. Need %u bytes but only have %u bytes\n", 
-                    firmwareSize, maxAppSpace);
-        return;
-    }
-
-    if (!Update.begin(firmwareSize)) {
-        Update.printError(Serial);
-        return;
-    }
-
-    size_t written = Update.writeStream(firmwareFile);
-    if (written != firmwareSize) {
-        Update.printError(Serial);
-        return;
-    }
-
-    if (!Update.end(true)) {
-        Update.printError(Serial);
-        return;
-    }
-
-    firmwareFile.close();
-    SPIFFS.remove("/firmware.bin"); // Cleanup
-    Serial.println("Stage 2 update successful, restarting...");
-    delay(500);
-    ESP.restart();
-}
-
-void checkForStagedUpdate() {
-    if (!SPIFFS.begin(true)) {
-        return;
-    }
-
-    if (SPIFFS.exists("/firmware.bin")) {
-        Serial.println("Found staged firmware update, initiating stage 2...");
-        performStageTwo();
-    }
-}
-
 void handleOTAUpload(AsyncWebServerRequest *request, String filename, size_t index, uint8_t *data, size_t len, bool final) {
-    static File stagingFile;
-    
     if (!index) {
-        bool isSpiffsUpdate = filename.endsWith("_spiffs.bin");
+        bool isFullImage = filename.endsWith(".bin");
-        Serial.printf("Update Start: %s (type: %s)\n", filename.c_str(), isSpiffsUpdate ? "SPIFFS" : "OTA");
+        Serial.printf("Update Start: %s (type: %s)\n", filename.c_str(), isFullImage ? "full" : "OTA");
         
         if (request->contentLength() == 0) {
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid file size\"}");
             return;
         }
 
-        // Stop tasks before update
+        // Berechne verfügbaren Speicherplatz
+        size_t updateSize = request->contentLength();
+        size_t maxSketchSpace = (ESP.getFreeSketchSpace() - 0x1000) & 0xFFFFF000;
+        
+        Serial.printf("Update size: %u bytes\n", updateSize);
+        Serial.printf("Available space: %u bytes\n", maxSketchSpace);
+        
+        if (updateSize > maxSketchSpace) {
+            Serial.printf("Error: Not enough space. Need %u bytes but only have %u bytes available\n", 
+                        updateSize, maxSketchSpace);
+            request->send(400, "application/json", 
+                        "{\"status\":\"error\",\"message\":\"Not enough space for update\"}");
+            return;
+        }
+
         if (!tasksAreStopped && (RfidReaderTask || BambuMqttTask || ScaleTask)) {
             stopAllTasks();
             tasksAreStopped = true;
         }
 
-        size_t updateSize = request->contentLength();
+        // Ensure SPIFFS is ended before update
+        if (SPIFFS.begin()) {
+            SPIFFS.end();
+        }
 
-        if (isSpiffsUpdate) {
+        bool success;
-            if (!SPIFFS.begin(true)) {
+        if (isFullImage) {
-                request->send(400, "application/json", 
+            success = Update.begin(updateSize, U_FLASH);
-                            "{\"status\":\"error\",\"message\":\"Could not mount SPIFFS\"}");
-                return;
-            }
-            
-            // Start SPIFFS update
-            if (!Update.begin(updateSize, U_SPIFFS)) {
-                Update.printError(Serial);
-                request->send(400, "application/json", 
-                            "{\"status\":\"error\",\"message\":\"SPIFFS update initialization failed\"}");
-                return;
-            }
         } else {
-            // Regular OTA update
+            if (data[0] != 0xE9) {
-            stagingFile = SPIFFS.open("/firmware.bin", "w");
+                Serial.printf("Wrong magic byte: 0x%02X (expected 0xE9)\n", data[0]);
-            if (!stagingFile) {
                 request->send(400, "application/json", 
-                            "{\"status\":\"error\",\"message\":\"Could not create staging file\"}");
+                            "{\"status\":\"error\",\"message\":\"Invalid firmware format\"}");
                 return;
             }
+            success = Update.begin(updateSize);
+        }
+
+        if (!success) {
+            Update.printError(Serial);
+            request->send(400, "application/json", 
+                        "{\"status\":\"error\",\"message\":\"Update initialization failed\"}");
+            return;
         }
     }
 
-    if (stagingFile) {
+    if (Update.write(data, len) != len) {
-        // Stage 1: Write to SPIFFS
+        Update.printError(Serial);
-        if (stagingFile.write(data, len) != len) {
+        request->send(400, "application/json", 
-            stagingFile.close();
+                    "{\"status\":\"error\",\"message\":\"Write failed\"}");
-            SPIFFS.remove("/firmware.bin");
+        return;
-            request->send(400, "application/json", 
-                        "{\"status\":\"error\",\"message\":\"Write to SPIFFS failed\"}");
-            return;
-        }
-    } else {
-        // Direct SPIFFS update
-        if (Update.write(data, len) != len) {
-            Update.printError(Serial);
-            request->send(400, "application/json", 
-                        "{\"status\":\"error\",\"message\":\"Write failed\"}");
-            return;
-        }
     }
 
     if (final) {
-        if (stagingFile) {
+        if (!Update.end(true)) {
-            // Finish Stage 1
+            Update.printError(Serial);
-            stagingFile.close();
+            request->send(400, "application/json", 
-            Serial.println("Stage 1 complete - firmware staged in SPIFFS");
+                        "{\"status\":\"error\",\"message\":\"Update failed\"}");
-            request->send(200, "application/json", 
+            return;
-                        "{\"status\":\"success\",\"message\":\"Update staged successfully! Starting stage 2...\"}");
-            performStageTwo();
-        } else {
-            // Finish direct SPIFFS update
-            if (!Update.end(true)) {
-                Update.printError(Serial);
-                request->send(400, "application/json", 
-                            "{\"status\":\"error\",\"message\":\"Update failed\"}");
-                return;
-            }
-            Serial.println("SPIFFS update successful, restarting...");
-            request->send(200, "application/json", 
-                        "{\"status\":\"success\",\"message\":\"SPIFFS update successful! Device will restart...\",\"restart\":true}");
-            delay(500);
-            ESP.restart();
         }
+        Serial.println("Update successful, restarting...");
+        request->send(200, "application/json", 
+                    "{\"status\":\"success\",\"message\":\"Update successful! Device will restart...\",\"restart\":true}");
+        delay(500);
+        ESP.restart();
     }
 }