Complete Rebuild, with Subsystems for each component. RTOS Tasks. (help by Claude)

This commit is contained in:
2025-10-01 12:42:00 +03:00
parent 104c1d04d4
commit f696984cd1
57 changed files with 11757 additions and 2290 deletions

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#include "OTAManager.hpp"
#include "../ConfigManager/ConfigManager.hpp"
#include "../Logging/Logging.hpp"
#include <nvs_flash.h>
#include <nvs.h>
OTAManager::OTAManager(ConfigManager& configManager)
: _configManager(configManager)
, _fileManager(nullptr)
, _status(Status::IDLE)
, _lastError(ErrorCode::NONE)
, _availableVersion(0.0f)
, _updateAvailable(false)
, _availableChecksum("")
, _updateChannel("stable")
, _isMandatory(false)
, _isEmergency(false)
, _progressCallback(nullptr)
, _statusCallback(nullptr) {
}
void OTAManager::begin() {
LOG_INFO("OTA Manager initialized");
setStatus(Status::IDLE);
}
void OTAManager::setFileManager(FileManager* fm) {
_fileManager = fm;
}
void OTAManager::checkForUpdates() {
// Boot-time check: only check stable channel for emergency/mandatory updates
checkForUpdates("stable");
}
void OTAManager::checkForUpdates(const String& channel) {
if (_status != Status::IDLE) {
LOG_WARNING("OTA check already in progress");
return;
}
setStatus(Status::CHECKING_VERSION);
LOG_INFO("Checking for firmware updates in %s channel for %s...",
channel.c_str(), _configManager.getHardwareVariant().c_str());
if (checkVersion(channel)) {
float currentVersion = getCurrentVersion();
LOG_INFO("Current version: %.1f, Available version: %.1f (Channel: %s)",
currentVersion, _availableVersion, channel.c_str());
if (_availableVersion > currentVersion) {
_updateAvailable = true;
LOG_INFO("New version available! Mandatory: %s, Emergency: %s",
_isMandatory ? "YES" : "NO", _isEmergency ? "YES" : "NO");
setStatus(Status::IDLE);
// Auto-update for emergency or mandatory updates during boot check
if (channel == "stable" && (_isEmergency || _isMandatory)) {
LOG_INFO("Emergency/Mandatory update detected - starting automatic update");
update(channel);
}
} else {
_updateAvailable = false;
LOG_INFO("No new version available");
setStatus(Status::IDLE);
}
} else {
_updateAvailable = false;
setStatus(Status::FAILED, _lastError);
}
}
void OTAManager::update() {
update("stable"); // Default to stable channel
}
void OTAManager::update(const String& channel) {
if (_status != Status::IDLE) {
LOG_WARNING("OTA update already in progress");
return;
}
if (!_updateAvailable) {
LOG_WARNING("No update available for channel: %s", channel.c_str());
return;
}
LOG_INFO("Starting OTA update from %s channel...", channel.c_str());
setStatus(Status::DOWNLOADING);
if (downloadAndInstall(channel)) {
setStatus(Status::SUCCESS);
LOG_INFO("Update successfully finished. Rebooting...");
delay(1000);
ESP.restart();
} else {
setStatus(Status::FAILED, _lastError);
}
}
float OTAManager::getCurrentVersion() const {
String fwVersionStr = _configManager.getFwVersion();
return fwVersionStr.toFloat();
}
void OTAManager::setStatus(Status status, ErrorCode error) {
_status = status;
_lastError = error;
if (_statusCallback) {
_statusCallback(status, error);
}
}
void OTAManager::notifyProgress(size_t current, size_t total) {
if (_progressCallback) {
_progressCallback(current, total);
}
}
// Enhanced version checking with channel support and multiple servers
bool OTAManager::checkVersion(const String& channel) {
std::vector<String> servers = _configManager.getUpdateServers();
auto& updateConfig = _configManager.getUpdateConfig();
for (size_t serverIndex = 0; serverIndex < servers.size(); serverIndex++) {
String baseUrl = servers[serverIndex];
String metadataUrl = baseUrl + "/ota/" + _configManager.getHardwareVariant() + "/" + channel + "/metadata.json";
LOG_INFO("OTA: Trying server %d/%d: %s", serverIndex + 1, servers.size(), baseUrl.c_str());
HTTPClient http;
http.setTimeout(updateConfig.timeout);
http.begin(metadataUrl.c_str());
int retryCount = 0;
int httpCode = -1;
// Retry logic for current server
while (retryCount < updateConfig.retries && httpCode != HTTP_CODE_OK) {
if (retryCount > 0) {
LOG_INFO("OTA: Retry %d/%d for %s", retryCount + 1, updateConfig.retries, baseUrl.c_str());
delay(1000 * retryCount); // Exponential backoff
}
httpCode = http.GET();
retryCount++;
}
if (httpCode == HTTP_CODE_OK) {
String jsonStr = http.getString();
http.end();
// Parse JSON metadata
DynamicJsonDocument doc(1024);
DeserializationError error = deserializeJson(doc, jsonStr);
if (error) {
LOG_ERROR("OTA: Failed to parse metadata JSON from %s: %s",
baseUrl.c_str(), error.c_str());
continue; // Try next server
}
// Extract metadata
_availableVersion = doc["version"].as<float>();
_availableChecksum = doc["checksum"].as<String>();
_updateChannel = doc["channel"].as<String>();
_isMandatory = doc["mandatory"].as<bool>();
_isEmergency = doc["emergency"].as<bool>();
// Validate hardware variant matches
String hwVariant = doc["hardwareVariant"].as<String>();
String ourHardwareVariant = _configManager.getHardwareVariant();
if (!hwVariant.isEmpty() && hwVariant != ourHardwareVariant) {
LOG_ERROR("OTA: Hardware variant mismatch! Expected: %s, Got: %s",
ourHardwareVariant.c_str(), hwVariant.c_str());
continue; // Try next server
}
if (_availableVersion == 0.0f) {
LOG_ERROR("OTA: Invalid version in metadata from %s", baseUrl.c_str());
continue; // Try next server
}
if (_availableChecksum.length() != 64) { // SHA256 is 64 hex characters
LOG_ERROR("OTA: Invalid checksum in metadata from %s", baseUrl.c_str());
continue; // Try next server
}
LOG_INFO("OTA: Successfully got metadata from %s", baseUrl.c_str());
return true; // Success!
} else {
LOG_ERROR("OTA: Server %s failed after %d retries. HTTP error: %d",
baseUrl.c_str(), updateConfig.retries, httpCode);
http.end();
}
}
// All servers failed
LOG_ERROR("OTA: All %d servers failed to provide metadata", servers.size());
_lastError = ErrorCode::HTTP_ERROR;
return false;
}
// Enhanced download and install with channel support and multiple servers
bool OTAManager::downloadAndInstall(const String& channel) {
std::vector<String> servers = _configManager.getUpdateServers();
for (size_t serverIndex = 0; serverIndex < servers.size(); serverIndex++) {
String baseUrl = servers[serverIndex];
String firmwareUrl = baseUrl + "/ota/" + _configManager.getHardwareVariant() + "/" + channel + "/firmware.bin";
LOG_INFO("OTA: Trying firmware download from server %d/%d: %s",
serverIndex + 1, servers.size(), baseUrl.c_str());
if (downloadToSD(firmwareUrl, _availableChecksum)) {
// Success! Now install from SD
return installFromSD("/firmware/staged_update.bin");
} else {
LOG_WARNING("OTA: Firmware download failed from %s, trying next server", baseUrl.c_str());
}
}
// All servers failed
LOG_ERROR("OTA: All %d servers failed to provide firmware", servers.size());
return false;
}
bool OTAManager::downloadToSD(const String& url, const String& expectedChecksum) {
// This method now receives the exact firmware URL from downloadAndInstall
// The server selection logic is handled there
if (!_fileManager) {
LOG_ERROR("FileManager not set!");
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
return false;
}
// Ensure firmware directory exists
_fileManager->createDirectory("/firmware");
// Download to temporary file
String tempPath = "/firmware/staged_update.bin";
HTTPClient http;
http.begin(url.c_str());
int httpCode = http.GET();
if (httpCode != HTTP_CODE_OK) {
LOG_ERROR("Download HTTP error code: %d", httpCode);
setStatus(Status::FAILED, ErrorCode::HTTP_ERROR);
http.end();
return false;
}
int contentLength = http.getSize();
if (contentLength <= 0) {
LOG_ERROR("Invalid content length");
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
http.end();
return false;
}
// Open file for writing
File file = SD.open(tempPath.c_str(), FILE_WRITE);
if (!file) {
LOG_ERROR("Failed to create temporary update file");
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
http.end();
return false;
}
WiFiClient* stream = http.getStreamPtr();
uint8_t buffer[1024];
size_t written = 0;
while (http.connected() && written < contentLength) {
size_t available = stream->available();
if (available) {
size_t toRead = min(available, sizeof(buffer));
size_t bytesRead = stream->readBytes(buffer, toRead);
if (bytesRead > 0) {
size_t bytesWritten = file.write(buffer, bytesRead);
if (bytesWritten != bytesRead) {
LOG_ERROR("SD write failed");
file.close();
http.end();
setStatus(Status::FAILED, ErrorCode::WRITE_FAILED);
return false;
}
written += bytesWritten;
notifyProgress(written, contentLength);
}
}
yield();
}
file.close();
http.end();
if (written != contentLength) {
LOG_ERROR("Download incomplete: %d/%d bytes", written, contentLength);
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
return false;
}
LOG_INFO("Download complete (%d bytes)", written);
// Verify checksum
if (!verifyChecksum(tempPath, expectedChecksum)) {
LOG_ERROR("Checksum verification failed after download");
_fileManager->deleteFile(tempPath);
setStatus(Status::FAILED, ErrorCode::CHECKSUM_MISMATCH);
return false;
}
LOG_INFO("Download and checksum verification successful");
return true;
}
bool OTAManager::verifyChecksum(const String& filePath, const String& expectedChecksum) {
String calculatedChecksum = calculateSHA256(filePath);
if (calculatedChecksum.isEmpty()) {
LOG_ERROR("Failed to calculate checksum");
return false;
}
bool match = calculatedChecksum.equalsIgnoreCase(expectedChecksum);
if (match) {
LOG_INFO("Checksum verification passed");
} else {
LOG_ERROR("Checksum mismatch!");
LOG_ERROR("Expected: %s", expectedChecksum.c_str());
LOG_ERROR("Calculated: %s", calculatedChecksum.c_str());
}
return match;
}
String OTAManager::calculateSHA256(const String& filePath) {
File file = SD.open(filePath.c_str());
if (!file) {
LOG_ERROR("Failed to open file for checksum calculation: %s", filePath.c_str());
return "";
}
mbedtls_md_context_t ctx;
mbedtls_md_type_t md_type = MBEDTLS_MD_SHA256;
mbedtls_md_init(&ctx);
mbedtls_md_setup(&ctx, mbedtls_md_info_from_type(md_type), 0);
mbedtls_md_starts(&ctx);
uint8_t buffer[1024];
size_t bytesRead;
while ((bytesRead = file.readBytes((char*)buffer, sizeof(buffer))) > 0) {
mbedtls_md_update(&ctx, buffer, bytesRead);
}
uint8_t hash[32];
mbedtls_md_finish(&ctx, hash);
mbedtls_md_free(&ctx);
file.close();
// Convert to hex string
String hashString = "";
for (int i = 0; i < 32; i++) {
String hex = String(hash[i], HEX);
if (hex.length() == 1) {
hex = "0" + hex;
}
hashString += hex;
}
return hashString;
}
bool OTAManager::installFromSD(const String& filePath) {
size_t updateSize = _fileManager->getFileSize(filePath);
if (updateSize == 0) {
LOG_ERROR("Empty update file");
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
return false;
}
LOG_INFO("Installing firmware from SD (%u bytes)...", updateSize);
setStatus(Status::INSTALLING);
if (!Update.begin(updateSize)) {
LOG_ERROR("Not enough space to begin update");
setStatus(Status::FAILED, ErrorCode::INSUFFICIENT_SPACE);
return false;
}
File updateBin = SD.open(filePath.c_str());
if (!updateBin) {
LOG_ERROR("Failed to open update file: %s", filePath.c_str());
setStatus(Status::FAILED, ErrorCode::DOWNLOAD_FAILED);
return false;
}
size_t written = Update.writeStream(updateBin);
updateBin.close();
if (written == updateSize) {
LOG_INFO("Update written successfully (%u bytes)", written);
} else {
LOG_ERROR("Written only %u/%u bytes", written, updateSize);
setStatus(Status::FAILED, ErrorCode::WRITE_FAILED);
return false;
}
if (Update.end(true)) { // true = set new boot partition
LOG_INFO("Update finished!");
if (Update.isFinished()) {
setStatus(Status::SUCCESS);
LOG_INFO("Update complete. Cleaning up and rebooting...");
// Clean up the update files
_fileManager->deleteFile(filePath);
_fileManager->deleteFile("/firmware/staged_update.sha256");
_fileManager->deleteFile("/firmware/update.sha256");
// Clear firmware validation state to force validation of new firmware
nvs_handle_t nvsHandle;
esp_err_t err = nvs_open("fw_validator", NVS_READWRITE, &nvsHandle);
if (err == ESP_OK) {
nvs_erase_key(nvsHandle, "val_state");
nvs_erase_key(nvsHandle, "retry_count");
nvs_erase_key(nvsHandle, "fail_count");
nvs_commit(nvsHandle);
nvs_close(nvsHandle);
LOG_INFO("✅ OTA: Firmware validation state cleared - new firmware will be validated");
} else {
LOG_WARNING("⚠️ OTA: Failed to clear validation state: %s", esp_err_to_name(err));
}
delay(1000);
_configManager.setFwVersion(String(_availableVersion, 1)); // 1 decimal place
_configManager.saveDeviceConfig();
delay(500);
ESP.restart();
return true;
} else {
LOG_ERROR("Update not complete");
setStatus(Status::FAILED, ErrorCode::VERIFICATION_FAILED);
return false;
}
} else {
LOG_ERROR("Update error: %s", Update.errorString());
setStatus(Status::FAILED, ErrorCode::VERIFICATION_FAILED);
return false;
}
}
void OTAManager::checkFirmwareUpdateFromSD() {
if (!_fileManager) {
LOG_ERROR("FileManager not set!");
return;
}
if (!_fileManager->fileExists("/firmware/update.bin")) {
LOG_DEBUG("No update.bin found on SD card");
return;
}
// Check for checksum file
String checksumFile = "/firmware/update.sha256";
if (!_fileManager->fileExists(checksumFile)) {
LOG_WARNING("No checksum file found, proceeding without verification");
installFromSD("/firmware/update.bin");
return;
}
// Read expected checksum
File checksumFileHandle = SD.open(checksumFile.c_str());
if (!checksumFileHandle) {
LOG_ERROR("Failed to open checksum file");
return;
}
String expectedChecksum = checksumFileHandle.readString();
checksumFileHandle.close();
expectedChecksum.trim();
// Verify checksum
if (!verifyChecksum("/firmware/update.bin", expectedChecksum)) {
LOG_ERROR("Checksum verification failed, aborting update");
setStatus(Status::FAILED, ErrorCode::CHECKSUM_MISMATCH);
return;
}
LOG_INFO("Checksum verified, proceeding with update");
installFromSD("/firmware/update.bin");
}
bool OTAManager::performManualUpdate() {
return performManualUpdate("stable");
}
bool OTAManager::performManualUpdate(const String& channel) {
if (_status != Status::IDLE) {
LOG_WARNING("OTA update already in progress");
return false;
}
// Check for updates in the specified channel first
checkForUpdates(channel);
if (!_updateAvailable) {
LOG_WARNING("No update available in %s channel", channel.c_str());
return false;
}
LOG_INFO("Starting manual OTA update from %s channel via SD staging...", channel.c_str());
setStatus(Status::DOWNLOADING);
String firmwareUrl = buildFirmwareUrl(channel);
// Download to SD first
if (!downloadToSD(firmwareUrl, _availableChecksum)) {
return false;
}
// Install from SD
return installFromSD("/firmware/staged_update.bin");
}
// Hardware variant management
String OTAManager::getHardwareVariant() const {
return _configManager.getHardwareVariant();
}
void OTAManager::setHardwareVariant(const String& variant) {
LOG_WARNING("OTAManager::setHardwareVariant is deprecated. Use ConfigManager::setHardwareVariant instead");
// For backward compatibility, we could call configManager, but it's better to use ConfigManager directly
}
// URL builders for multi-channel architecture
String OTAManager::buildChannelUrl(const String& channel) const {
auto& updateConfig = _configManager.getUpdateConfig();
String baseUrl = updateConfig.fallbackServerUrl;
return baseUrl + "/" + _configManager.getHardwareVariant() + "/" + channel + "/";
}
String OTAManager::buildMetadataUrl(const String& channel) const {
return buildChannelUrl(channel) + "metadata.json";
}
String OTAManager::buildFirmwareUrl(const String& channel) const {
return buildChannelUrl(channel) + "firmware.bin";
}
// ════════════════════════════════════════════════════════════════════════════
// HEALTH CHECK IMPLEMENTATION
// ════════════════════════════════════════════════════════════════════════════
bool OTAManager::isHealthy() const {
// Check if FileManager dependency is set
if (!_fileManager) {
LOG_DEBUG("OTAManager: Unhealthy - FileManager not set");
return false;
}
// Check if we're not in a failed state
if (_status == Status::FAILED) {
LOG_DEBUG("OTAManager: Unhealthy - In failed state");
return false;
}
// Check if ConfigManager has valid configuration
String hwVariant = _configManager.getHardwareVariant();
if (hwVariant.isEmpty() || hwVariant == "BellSystems") {
LOG_DEBUG("OTAManager: Unhealthy - Invalid hardware variant: %s", hwVariant.c_str());
return false;
}
String fwVersion = _configManager.getFwVersion();
if (fwVersion.isEmpty() || fwVersion == "0") {
LOG_DEBUG("OTAManager: Unhealthy - Invalid firmware version: %s", fwVersion.c_str());
return false;
}
// Check if update servers are available
std::vector<String> servers = _configManager.getUpdateServers();
if (servers.empty()) {
LOG_DEBUG("OTAManager: Unhealthy - No update servers configured");
return false;
}
// Check if FileManager is healthy (can access SD card)
if (!_fileManager->isHealthy()) {
LOG_DEBUG("OTAManager: Unhealthy - FileManager is unhealthy");
return false;
}
return true;
}