docs: update changelog for version 1.2.91

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

@@ -39,38 +39,42 @@ jobs:
     
     - name: Build Firmware
       run: |
-        pio run -e esp32dev_ota -t buildfs  # Build SPIFFS
-        pio run -e esp32dev_ota            # Build firmware
-        cp .pio/build/esp32dev_ota/firmware.bin .pio/build/esp32dev_ota/filaman.bin
-        cp .pio/build/esp32dev_ota/spiffs.bin .pio/build/esp32dev_ota/filaman_spiffs.bin
+        pio run -e esp32dev -t buildfs  # Build SPIFFS
+        pio run -e esp32dev            # Build firmware
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman.bin
+        cp .pio/build/esp32dev/spiffs.bin .pio/build/esp32dev/filaman_spiffs.bin
         
     - name: Prepare binaries
       run: |
-        cd .pio/build/esp32dev_ota
+        # Ensure we're in the project root
+        cd $GITHUB_WORKSPACE
         
-        # Create OTA binary (already has correct magic byte)
-        cp firmware.bin filaman_ota.bin
+        # Create SPIFFS directory if it doesn't exist
+        mkdir -p .pio/build/esp32dev/spiffs
         
-        # Create a magic byte prepended binary for the bootloader
-        echo -ne '\xE9' > bootloader_with_magic.bin
-        cat bootloader.bin >> bootloader_with_magic.bin
+        # Copy firmware to SPIFFS directory
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/spiffs/firmware.bin
         
-        echo "Creating full binary with magic byte..."
+        # Build new SPIFFS image with firmware included
+        pio run -t buildfs
+        
+        cd .pio/build/esp32dev
+        
+        # Create release files
+        cp spiffs.bin filaman_spiffs.bin
+        
+        # Create full binary
+        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 \
-          0x0000 bootloader_with_magic.bin \
+          0x0000 bootloader.bin \
           0x8000 partitions.bin \
           0x10000 firmware.bin \
-          0x3D0000 spiffs.bin
-        
-        # Verify magic bytes
-        echo "Checking magic bytes:"
-        echo "Full binary first bytes:"
-        xxd -l 16 filaman_full.bin
+          0x390000 spiffs.bin
         
         # Verify file sizes
         echo "File sizes:"
@@ -102,15 +106,21 @@ jobs:
           echo "Release created with ID: $RELEASE_ID"
           
           # Upload binaries
-          cd .pio/build/esp32dev_ota
-          for file in filaman_full.bin; do
-            echo "Uploading $file..."
-            curl -k -s \
-              -X POST \
-              -H "Authorization: token ${TOKEN}" \
-              -H "Content-Type: application/octet-stream" \
-              --data-binary "@$file" \
-              "${API_URL}/repos/${REPO}/releases/${RELEASE_ID}/assets?name=$file"
+          cd .pio/build/esp32dev
+          
+          # Check if files exist before uploading
+          for file in filaman_spiffs.bin filaman_full.bin; do
+            if [ -f "$file" ]; then
+              echo "Uploading $file..."
+              curl -k -s \
+                -X POST \
+                -H "Authorization: token ${TOKEN}" \
+                -H "Content-Type: application/octet-stream" \
+                --data-binary "@$file" \
+                "${API_URL}/repos/${REPO}/releases/${RELEASE_ID}/assets?name=$file"
+            else
+              echo "Warning: $file not found"
+            fi
           done
         else
           echo "Failed to create release. Response:"

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

@@ -28,38 +28,42 @@ jobs:
     
     - name: Build Firmware
       run: |
-        pio run -e esp32dev_ota -t buildfs  # Build SPIFFS
-        pio run -e esp32dev_ota            # Build firmware
-        cp .pio/build/esp32dev_ota/firmware.bin .pio/build/esp32dev_ota/filaman.bin
-        cp .pio/build/esp32dev_ota/spiffs.bin .pio/build/esp32dev_ota/filaman_spiffs.bin
+        pio run -e esp32dev -t buildfs  # Build SPIFFS
+        pio run -e esp32dev            # Build firmware
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/filaman.bin
+        cp .pio/build/esp32dev/spiffs.bin .pio/build/esp32dev/filaman_spiffs.bin
         
     - name: Prepare binaries
       run: |
-        cd .pio/build/esp32dev_ota
+        # Ensure we're in the project root
+        cd $GITHUB_WORKSPACE
         
-        # Create OTA binary (already has correct magic byte)
-        cp firmware.bin filaman_ota.bin
+        # Create SPIFFS directory if it doesn't exist
+        mkdir -p .pio/build/esp32dev/spiffs
         
-        # Create a magic byte prepended binary for the bootloader
-        echo -ne '\xE9' > bootloader_with_magic.bin
-        cat bootloader.bin >> bootloader_with_magic.bin
+        # Copy firmware to SPIFFS directory
+        cp .pio/build/esp32dev/firmware.bin .pio/build/esp32dev/spiffs/firmware.bin
         
-        echo "Creating full binary with magic byte..."
+        # Build new SPIFFS image with firmware included
+        pio run -t buildfs
+        
+        cd .pio/build/esp32dev
+        
+        # Create release files
+        cp spiffs.bin filaman_spiffs.bin
+        
+        # Create full binary
+        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 \
-          0x0000 bootloader_with_magic.bin \
+          0x0000 bootloader.bin \
           0x8000 partitions.bin \
           0x10000 firmware.bin \
-          0x3D0000 spiffs.bin
-        
-        # Verify magic bytes
-        echo "Checking magic bytes:"
-        echo "Full binary first bytes:"
-        xxd -l 16 filaman_full.bin
+          0x390000 spiffs.bin
         
         # Verify file sizes
         echo "File sizes:"
@@ -83,7 +87,23 @@ jobs:
       env:
         GH_TOKEN: ${{ github.token }}
       run: |
-        gh release create "${{ github.ref_name }}" \
-          --title "Release ${{ steps.get_version.outputs.VERSION }}" \
-          --notes "${{ steps.changelog.outputs.CHANGES }}" \
-          .pio/build/esp32dev_ota/filaman_full.bin
+        # Check which files exist and create a list for upload
+        cd .pio/build/esp32dev
+        FILES_TO_UPLOAD=""
+        for file in filaman_spiffs.bin filaman_full.bin; do
+          if [ -f "$file" ]; then
+            FILES_TO_UPLOAD="$FILES_TO_UPLOAD .pio/build/esp32dev/$file"
+          else
+            echo "Warning: $file not found"
+          fi
+        done
+        
+        # Create release with available files
+        if [ -n "$FILES_TO_UPLOAD" ]; then
+          gh release create "${{ github.ref_name }}" \
+            --title "Release ${{ steps.get_version.outputs.VERSION }}" \
+            --notes "${{ steps.changelog.outputs.CHANGES }}" \
+            $FILES_TO_UPLOAD
+        else
+          echo "Error: No files found to upload"
+          exit 1

CHANGELOG.md

@@ -1,5 +1,49 @@
 # Changelog
 
+## [1.2.91] - 2025-02-20
+### Added
+- add file existence checks before uploading binaries in release workflows
+
+### Changed
+- update webpages for version v1.2.91
+
+
+## [1.2.90] - 2025-02-20
+### Changed
+- update webpages for version v1.2.90
+- update Gitea and GitHub release workflows to include SPIFFS directory creation and firmware copying
+
+
+## [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
+
+### Fixed
+- improve OTA update handling and logging for better error reporting
+
+
+## [1.2.87] - 2025-02-20
+### Changed
+- update webpages for version v1.2.87
+
+### Fixed
+- update firmware build process and remove unused OTA environment
+
+
+## [1.2.86] - 2025-02-20
+### Changed
+- update webpages for version v1.2.86
+
+### Fixed
+- update SPIFFS offset and size in release workflows and partitions.csv
+
+
 ## [1.2.85] - 2025-02-20
 ### Added
 - ci: streamline release workflows by removing unnecessary binary uploads and adding SPIFFS formatting

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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</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">v1.2.85</span></h1>
+                <h1>FilaMan<span class="version">v1.2.91</span></h1>
                 <h4>Filament Management Tool</h4>
             </div>
         </div>

partitions.csv

@@ -1,6 +1,6 @@
 # Name,   Type, SubType,    Offset,   Size,     Flags
 nvs,      data, nvs,       0x9000,   0x5000,
 otadata,  data, ota,       0xe000,   0x2000,
-app0,     app,  ota_0,     0x10000,  0x1E0000,
-app1,     app,  ota_1,     0x1F0000, 0x1E0000,
-spiffs,   data, spiffs,    0x3D0000, 0x30000,
+app0,     app,  ota_0,     0x10000,  0x1C0000,
+app1,     app,  ota_1,     0x1D0000, 0x1C0000,
+spiffs,   data, spiffs,    0x390000, 0x60000,

platformio.ini

@@ -9,7 +9,7 @@
 ; https://docs.platformio.org/page/projectconf.html
 
 [common]
-version = "1.2.85"
+version = "1.2.91"
 
 [env:esp32dev]
 platform = espressif32
@@ -45,74 +45,7 @@ build_flags =
     -mtext-section-literals
     '-D VERSION="${common.version}"'
     -DASYNCWEBSERVER_REGEX
-    -DCORE_DEBUG_LEVEL=1
-    -DCONFIG_ARDUHAL_LOG_COLORS=1
-    -DOTA_DEBUG=1
-    -DARDUINO_RUNNING_CORE=1
-    -DARDUINO_EVENT_RUNNING_CORE=1
-    -DCONFIG_OPTIMIZATION_LEVEL_DEBUG=1
-    -DCONFIG_ESP32_PANIC_PRINT_REBOOT
-    -DCONFIG_ARDUINO_OTA_READSIZE=1024
-    -DCONFIG_ASYNC_TCP_RUNNING_CORE=1
-    -DCONFIG_ASYNC_TCP_USE_WDT=0
-    -DCONFIG_LWIP_TCP_MSS=1460
-    -DOTA_PARTITION_SUBTYPE=0x10
-    -DPARTITION_TABLE_OFFSET=0x8000
-    -DPARTITION_TABLE_SIZE=0x1000
-    -DCONFIG_BOOTLOADER_APP_ROLLBACK_ENABLE=1
-    -DCONFIG_BOOTLOADER_SKIP_VALIDATE_IN_DEEP_SLEEP=1
-    -DCONFIG_BOOTLOADER_SKIP_VALIDATE_ON_POWER_ON=1
-    -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
-    pre:scripts/pre_build.py     ; wird zuerst ausgeführt
-    pre:scripts/pre_spiffs.py    ; wird als zweites ausgeführt
-    pre:scripts/combine_html.py  ; wird als drittes ausgeführt
-    scripts/gzip_files.py
-
-; Remove or comment out the targets line
-;targets = buildfs, build
-
-; Add a custom target to build both
-[env:esp32dev_ota]
-platform = espressif32
-board = esp32dev
-framework = arduino
-monitor_speed = 115200
-
-lib_deps =
-    tzapu/WiFiManager @ ^2.0.17
-    https://github.com/me-no-dev/ESPAsyncWebServer.git#master
-    me-no-dev/AsyncTCP @ ^1.1.1
-    bogde/HX711 @ ^0.7.5
-    adafruit/Adafruit SSD1306 @ ^2.5.13
-    adafruit/Adafruit GFX Library @ ^1.11.11
-    adafruit/Adafruit PN532 @ ^1.3.3
-    bblanchon/ArduinoJson @ ^7.3.0
-    knolleary/PubSubClient @ ^2.8
-    digitaldragon/SSLClient @ ^1.3.2
-    
-; Enable SPIFFS upload
-board_build.filesystem = spiffs
-; Update partition settings
-board_build.partitions = partitions.csv
-board_upload.flash_size = 4MB
-board_build.flash_mode = dio
-board_upload.flash_freq = "40m"
-
-build_flags = 
-    -Os
-    -ffunction-sections
-    -fdata-sections
-    -DNDEBUG
-    -mtext-section-literals
-    '-D VERSION="${common.version}"'
-    -DASYNCWEBSERVER_REGEX
-    -DCORE_DEBUG_LEVEL=1
+    -DCORE_DEBUG_LEVEL=3
     -DCONFIG_ARDUHAL_LOG_COLORS=1
     -DOTA_DEBUG=1
     -DARDUINO_RUNNING_CORE=1
@@ -133,6 +66,7 @@ build_flags =
     -DCONFIG_PARTITION_TABLE_OFFSET=0x8000
     -DCONFIG_PARTITION_TABLE_MD5=y
     -DBOOT_APP_PARTITION_OTA_0=1
+    -DCONFIG_LOG_DEFAULT_LEVEL=3
     
 extra_scripts = 
     scripts/extra_script.py
@@ -146,5 +80,5 @@ extra_scripts =
 
 ; Add a custom target to build both
 [platformio]
-default_envs = esp32dev, esp32dev_ota
+default_envs = esp32dev
 

src/ota.cpp

@@ -20,58 +20,150 @@ 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 isFullImage = filename.endsWith("full.bin");
-        Serial.printf("Update Start: %s (type: %s)\n", filename.c_str(), isFullImage ? "full" : "OTA");
+        bool isSpiffsUpdate = filename.endsWith("_spiffs.bin");
+        Serial.printf("Update Start: %s (type: %s)\n", filename.c_str(), isSpiffsUpdate ? "SPIFFS" : "OTA");
         
         if (request->contentLength() == 0) {
             request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid file size\"}");
             return;
         }
 
+        // Stop tasks before update
         if (!tasksAreStopped && (RfidReaderTask || BambuMqttTask || ScaleTask)) {
             stopAllTasks();
             tasksAreStopped = true;
         }
 
-        bool success;
-        if (isFullImage) {
-            // Full image update ohne Magic Byte Check, aber mit U_FLASH
-            success = Update.begin(UPDATE_SIZE_UNKNOWN, U_FLASH);
-        } else {
-            // Normales OTA update mit Magic Byte Check
-            if (data[0] != 0xE9) {
-                Serial.printf("Wrong magic byte: 0x%02X (expected 0xE9)\n", data[0]);
-                request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Invalid firmware format\"}");
+        size_t updateSize = request->contentLength();
+        
+        if (isSpiffsUpdate) {
+            if (!SPIFFS.begin(true)) {
+                request->send(400, "application/json", 
+                            "{\"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
+            stagingFile = SPIFFS.open("/firmware.bin", "w");
+            if (!stagingFile) {
+                request->send(400, "application/json", 
+                            "{\"status\":\"error\",\"message\":\"Could not create staging file\"}");
                 return;
             }
-            success = Update.begin(request->contentLength());
-        }
-
-        if (!success) {
-            Update.printError(Serial);
-            request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Update start failed\"}");
-            return;
         }
     }
 
-    if (Update.write(data, len) != len) {
-        Update.printError(Serial);
-        request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Write failed\"}");
-        return;
+    if (stagingFile) {
+        // Stage 1: Write to SPIFFS
+        if (stagingFile.write(data, len) != len) {
+            stagingFile.close();
+            SPIFFS.remove("/firmware.bin");
+            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 (!Update.end(true)) {
-            Update.printError(Serial);
-            request->send(400, "application/json", "{\"status\":\"error\",\"message\":\"Update failed\"}");
-            return;
+        if (stagingFile) {
+            // Finish Stage 1
+            stagingFile.close();
+            Serial.println("Stage 1 complete - firmware staged in SPIFFS");
+            request->send(200, "application/json", 
+                        "{\"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();
     }
 }