Merge pull request #118 from jpirnay/fix-ota-updater

feat: Try to support CaptivePortals

.github/workflows/release.yml

@@ -28,6 +28,9 @@ jobs:
       - name: Build CrossPoint
         run: pio run -e gh_release
 
+      - name: Patch min_chip_rev_full to 0
+        run: python3 scripts/patch_min_chip_rev.py .pio/build/gh_release/firmware.bin
+
       - name: Upload Artifacts
         uses: actions/upload-artifact@v4
         with:

.github/workflows/release_candidate.yml

@@ -35,6 +35,9 @@ jobs:
           CROSSPOINT_RC_HASH: ${{ env.SHORT_SHA }}
         run: pio run -e gh_release_rc
 
+      - name: Patch min_chip_rev_full to 0
+        run: python3 scripts/patch_min_chip_rev.py .pio/build/gh_release_rc/firmware.bin
+
       - name: Upload Artifacts
         uses: actions/upload-artifact@v4
         with:

lib/I18n/translations/english.yaml

@@ -534,3 +534,7 @@ STR_STAR_PAGE: "Star Page"
 STR_NO_STARRED_PAGES: "No starred pages"
 STR_RENAME: "Rename"
 STR_PAGE_PREFIX: "p"
+STR_CAPTIVE_PORTAL_DETECTED: "Login Required"
+STR_CAPTIVE_PORTAL_HINT_1: "Network requires browser login. On another device,"
+STR_CAPTIVE_PORTAL_HINT_2: "visit the URL below to authorize, then press OK."
+STR_CAPTIVE_PORTAL_DONE: "I'm authorized"

platformio.ini

@@ -3,7 +3,7 @@ default_envs = default
 extra_configs = platformio.local.ini
 
 [crosspoint]
-version = 1.38
+version = 1.36
 
 [base]
 platform = https://github.com/pioarduino/platform-espressif32/releases/download/55.03.37/platform-espressif32.zip

scripts/patch_min_chip_rev.py

@@ -0,0 +1,64 @@
+"""
+Patch min_chip_rev_full to 0 in a firmware.bin and recompute the appended
+SHA-256 digest so esp_image_verify() still passes.
+
+esp_image_header_t layout (24 bytes, all packed):
+  offset  0      magic (0xE9)
+  offset  1      segment_count
+  offset  2      spi_mode
+  offset  3      spi_speed:4 | spi_size:4
+  offset  4-7    entry_addr  (uint32 LE)
+  offset  8      wp_pin
+  offset  9-11   spi_pin_drv[3]
+  offset  12-13  chip_id     (uint16 LE)
+  offset  14     min_chip_rev (uint8, legacy)
+  offset  15-16  min_chip_rev_full (uint16 LE)  <-- patch target
+  offset  17-18  max_chip_rev_full (uint16 LE)
+  offset  19-22  reserved[4]
+  offset  23     hash_appended (uint8)
+
+When hash_appended == 1, the last 32 bytes of the image are the SHA-256 over
+bytes [0 .. len-33] (everything except the digest itself).  We recompute and
+overwrite those 32 bytes after patching the header.
+"""
+import hashlib
+import struct
+import sys
+
+MIN_CHIP_REV_FULL_OFFSET = 15  # byte offset of min_chip_rev_full in esp_image_header_t
+HASH_LEN = 32
+HASH_APPENDED_OFFSET = 23  # byte offset of hash_appended flag
+
+
+def patch(path: str) -> None:
+    with open(path, "r+b") as f:
+        data = bytearray(f.read())
+
+    if data[0] != 0xE9:
+        print(f"ERROR: {path}: not a valid ESP image (magic=0x{data[0]:02x})", file=sys.stderr)
+        sys.exit(1)
+
+    old = struct.unpack_from("<H", data, MIN_CHIP_REV_FULL_OFFSET)[0]
+    print(f"min_chip_rev_full: v{old // 100}.{old % 100} -> v0.0")
+    struct.pack_into("<H", data, MIN_CHIP_REV_FULL_OFFSET, 0)
+
+    hash_appended = data[HASH_APPENDED_OFFSET]
+    if hash_appended == 1:
+        # Digest covers everything except the last 32 bytes.
+        digest = hashlib.sha256(data[:-HASH_LEN]).digest()
+        data[-HASH_LEN:] = digest
+        print(f"SHA-256 recomputed and written to last {HASH_LEN} bytes")
+    else:
+        print("hash_appended=0, no digest to update")
+
+    with open(path, "wb") as f:
+        f.write(data)
+
+    print(f"Patched: {path}")
+
+
+if __name__ == "__main__":
+    if len(sys.argv) != 2:
+        print(f"Usage: {sys.argv[0]} <firmware.bin>", file=sys.stderr)
+        sys.exit(1)
+    patch(sys.argv[1])

src/activities/network/WifiSelectionActivity.cpp

@@ -1,8 +1,10 @@
 #include "WifiSelectionActivity.h"
 
 #include <GfxRenderer.h>
+#include <HTTPClient.h>
 #include <I18n.h>
 #include <Logging.h>
+#include <NetworkClient.h>
 #include <WiFi.h>
 #include <esp_mac.h>
 
@@ -13,6 +15,7 @@
 #include "activities/util/KeyboardEntryActivity.h"
 #include "components/UITheme.h"
 #include "fontIds.h"
+#include "util/QrUtils.h"
 
 namespace {
 
@@ -263,6 +266,35 @@ void WifiSelectionActivity::attemptConnection() {
   }
 }
 
+bool WifiSelectionActivity::checkCaptivePortal() {
+  // Probe a known HTTP endpoint that returns 204 on open internet.
+  // Captive portals intercept this and return a redirect (3xx) or 200 with a login page.
+  NetworkClient client;
+  HTTPClient http;
+  http.setFollowRedirects(HTTPC_DISABLE_FOLLOW_REDIRECTS);
+  http.setTimeout(5000);
+  if (!http.begin(client, "http://connectivitycheck.gstatic.com/generate_204")) {
+    return false;
+  }
+  const int code = http.GET();
+  String location = http.getLocation();
+  http.end();
+
+  if (code < 0) {
+    LOG_DBG("WIFI", "Captive portal probe failed (connection error %d)", code);
+    return false;
+  }
+
+  if (code == 204) {
+    return false;  // Open internet, no captive portal
+  }
+
+  // Any redirect or unexpected 200 means a captive portal is intercepting.
+  captivePortalUrl = location.length() > 0 ? location.c_str() : "http://connectivitycheck.gstatic.com/generate_204";
+  LOG_DBG("WIFI", "Captive portal detected (HTTP %d), URL: %s", code, captivePortalUrl.c_str());
+  return true;
+}
+
 void WifiSelectionActivity::checkConnectionStatus() {
   if (state != WifiSelectionState::CONNECTING && state != WifiSelectionState::AUTO_CONNECTING) {
     return;
@@ -285,6 +317,13 @@ void WifiSelectionActivity::checkConnectionStatus() {
       WIFI_STORE.setLastConnectedSsid(selectedSSID);
     }
 
+    // Check for captive portal before declaring success
+    if (checkCaptivePortal()) {
+      state = WifiSelectionState::CAPTIVE_PORTAL;
+      requestUpdate();
+      return;
+    }
+
     // If we entered a new password, ask if user wants to save it
     // Otherwise, immediately complete so parent can start web server
     if (!usedSavedPassword && !enteredPassword.empty()) {
@@ -404,6 +443,24 @@ void WifiSelectionActivity::loop() {
     return;
   }
 
+  // Handle captive portal state - user must authorize on another device
+  if (state == WifiSelectionState::CAPTIVE_PORTAL) {
+    if (mappedInput.wasPressed(MappedInputManager::Button::Confirm)) {
+      // User says they've completed browser auth - proceed as connected
+      if (!usedSavedPassword && !enteredPassword.empty()) {
+        state = WifiSelectionState::SAVE_PROMPT;
+        savePromptSelection = 0;
+        requestUpdate();
+      } else {
+        onComplete(true);
+      }
+    } else if (mappedInput.wasPressed(MappedInputManager::Button::Back)) {
+      WiFi.disconnect();
+      startWifiScan();
+    }
+    return;
+  }
+
   // Handle connected state (should not normally be reached - connection
   // completes immediately)
   if (state == WifiSelectionState::CONNECTED) {
@@ -539,6 +596,9 @@ void WifiSelectionActivity::render(RenderLock&&) {
     case WifiSelectionState::FORGET_PROMPT:
       renderForgetPrompt();
       break;
+    case WifiSelectionState::CAPTIVE_PORTAL:
+      renderCaptivePortal();
+      break;
   }
 
   renderer.displayBuffer();
@@ -719,6 +779,90 @@ void WifiSelectionActivity::renderForgetPrompt() const {
   GUI.drawButtonHints(renderer, labels.btn1, labels.btn2, labels.btn3, labels.btn4);
 }
 
+void WifiSelectionActivity::renderCaptivePortal() const {
+  const auto& metrics = UITheme::getInstance().getMetrics();
+  const Rect contentRect = UITheme::getContentRect(renderer, true, false);
+
+  const int pageWidth = renderer.getScreenWidth();
+  const int maxWidth = pageWidth - metrics.contentSidePadding * 2;
+  const int lh12 = renderer.getLineHeight(UI_12_FONT_ID);
+  const int lh10 = renderer.getLineHeight(UI_10_FONT_ID);
+  const int lhSmall = renderer.getLineHeight(SMALL_FONT_ID);
+  const int sp = metrics.verticalSpacing;
+  constexpr int QR_SIZE = 320;
+
+  // Pre-compute URL line count so we can vertically centre everything
+  const char* url = captivePortalUrl.c_str();
+  int urlLineCount = 0;
+  {
+    int rem = static_cast<int>(captivePortalUrl.size());
+    int off = 0;
+    while (rem > 0) {
+      int lo = 1, hi = rem;
+      while (lo < hi) {
+        const int mid = (lo + hi + 1) / 2;
+        char tmp[512];
+        snprintf(tmp, sizeof(tmp), "%.*s", mid, url + off);
+        if (renderer.getTextWidth(SMALL_FONT_ID, tmp) <= maxWidth)
+          lo = mid;
+        else
+          hi = mid - 1;
+      }
+      urlLineCount++;
+      off += lo;
+      rem -= lo;
+    }
+  }
+
+  const int totalHeight = lh12 + sp       // title
+                          + lh10          // hint line 1
+                          + lh10 + sp     // hint line 2
+                          + QR_SIZE + sp  // QR code
+                          + urlLineCount * lhSmall;
+
+  // contentRect covers the full screen minus button hints; subtract the header
+  // and sub-header that render() always draws above us.
+  const int contentTop = metrics.topPadding + metrics.headerHeight + metrics.tabBarHeight;
+  const int contentBottom = contentRect.y + contentRect.height;
+  int y = contentTop + (contentBottom - contentTop - totalHeight) / 2;
+
+  renderer.drawCenteredText(UI_12_FONT_ID, y, tr(STR_CAPTIVE_PORTAL_DETECTED), true, EpdFontFamily::BOLD);
+  y += lh12 + sp;
+  renderer.drawCenteredText(UI_10_FONT_ID, y, tr(STR_CAPTIVE_PORTAL_HINT_1));
+  y += lh10;
+  renderer.drawCenteredText(UI_10_FONT_ID, y, tr(STR_CAPTIVE_PORTAL_HINT_2));
+  y += lh10 + sp;
+
+  const int qrX = contentRect.x + (contentRect.width - QR_SIZE) / 2;
+  QrUtils::drawQrCode(renderer, Rect{qrX, y, QR_SIZE, QR_SIZE}, captivePortalUrl);
+  y += QR_SIZE + sp;
+
+  // Split URL into as many lines as needed
+  int remaining = static_cast<int>(captivePortalUrl.size());
+  int offset = 0;
+  while (remaining > 0) {
+    int lo = 1, hi = remaining;
+    while (lo < hi) {
+      const int mid = (lo + hi + 1) / 2;
+      char tmp[512];
+      snprintf(tmp, sizeof(tmp), "%.*s", mid, url + offset);
+      if (renderer.getTextWidth(SMALL_FONT_ID, tmp) <= maxWidth)
+        lo = mid;
+      else
+        hi = mid - 1;
+    }
+    char line[512];
+    snprintf(line, sizeof(line), "%.*s", lo, url + offset);
+    renderer.drawCenteredText(SMALL_FONT_ID, y, line);
+    y += lhSmall;
+    offset += lo;
+    remaining -= lo;
+  }
+
+  const auto labels = mappedInput.mapLabels(tr(STR_BACK), tr(STR_CAPTIVE_PORTAL_DONE), "", "");
+  GUI.drawButtonHints(renderer, labels.btn1, labels.btn2, labels.btn3, labels.btn4);
+}
+
 void WifiSelectionActivity::onComplete(const bool connected) {
   ActivityResult result;
   result.isCancelled = !connected;

src/activities/network/WifiSelectionActivity.h

@@ -28,7 +28,8 @@ enum class WifiSelectionState {
   CONNECTED,          // Successfully connected
   SAVE_PROMPT,        // Asking user if they want to save the password
   CONNECTION_FAILED,  // Connection failed
-  FORGET_PROMPT       // Asking user if they want to forget the network
+  FORGET_PROMPT,      // Asking user if they want to forget the network
+  CAPTIVE_PORTAL      // Connected but network requires web-based login
 };
 
 /**
@@ -87,14 +88,18 @@ class WifiSelectionActivity final : public Activity {
   void renderSavePrompt() const;
   void renderConnectionFailed() const;
   void renderForgetPrompt() const;
+  void renderCaptivePortal() const;
 
   void startWifiScan();
   void processWifiScanResults();
   void selectNetwork(int index);
   void attemptConnection();
   void checkConnectionStatus();
+  bool checkCaptivePortal();
   std::string getSignalStrengthIndicator(int32_t rssi) const;
 
+  std::string captivePortalUrl;
+
   void onComplete(bool connected);
 
  public:

src/activities/settings/OtaUpdateActivity.cpp

@@ -31,6 +31,7 @@ void OtaUpdateActivity::onWifiSelectionComplete(const bool success) {
     LOG_DBG("OTA", "Update check failed: %d", res);
     {
       RenderLock lock(*this);
+      failureReason = res;
       state = FAILED;
     }
     return;
@@ -126,6 +127,35 @@ void OtaUpdateActivity::render(RenderLock&&) {
     GUI.drawButtonHints(renderer, labels.btn1, labels.btn2, labels.btn3, labels.btn4);
   } else if (state == FAILED) {
     renderer.drawCenteredText(UI_10_FONT_ID, top, tr(STR_UPDATE_FAILED), true, EpdFontFamily::BOLD);
+    const char* reason = "";
+    switch (failureReason) {
+      case OtaUpdater::HTTP_ERROR:
+        reason = "Network error (HTTP request failed)";
+        break;
+      case OtaUpdater::JSON_PARSE_ERROR:
+        reason = "Could not parse release info";
+        break;
+      case OtaUpdater::UPDATE_OLDER_ERROR:
+        reason = "Available version is not newer";
+        break;
+      case OtaUpdater::OOM_ERROR:
+        reason = "Out of memory";
+        break;
+      case OtaUpdater::INTERNAL_UPDATE_ERROR:
+        reason = "Internal update error";
+        break;
+      case OtaUpdater::NO_UPDATE:
+        reason = "No firmware asset found";
+        break;
+      case OtaUpdater::VALIDATE_FAILED:
+        reason = "Bootloader incompatible - reflash via USB with PlatformIO";
+        break;
+      default:
+        break;
+    }
+    if (reason[0] != '\0') {
+      renderer.drawCenteredText(SMALL_FONT_ID, top + height + metrics.verticalSpacing, reason);
+    }
     const auto labels = mappedInput.mapLabels(tr(STR_BACK), "", "", "");
     GUI.drawButtonHints(renderer, labels.btn1, labels.btn2, labels.btn3, labels.btn4);
   } else if (state == FINISHED) {
@@ -140,22 +170,18 @@ void OtaUpdateActivity::loop() {
   // TODO @ngxson : refactor this logic later
   if (updater.getRender()) {
     requestUpdate();
+    updater.clearRender();
   }
 
   if (state == WAITING_CONFIRMATION) {
     if (mappedInput.wasPressed(MappedInputManager::Button::Confirm)) {
       LOG_DBG("OTA", "New update available, starting download...");
-      {
+      const auto beginResult = updater.beginInstallUpdate();
-        RenderLock lock(*this);
+      if (beginResult != OtaUpdater::UPDATE_IN_PROGRESS) {
-        state = UPDATE_IN_PROGRESS;
+        LOG_DBG("OTA", "Update begin failed: %d", beginResult);
-      }
-      requestUpdateAndWait();
-      const auto res = updater.installUpdate();
-
-      if (res != OtaUpdater::OK) {
-        LOG_DBG("OTA", "Update failed: %d", res);
         {
           RenderLock lock(*this);
+          failureReason = beginResult;
           state = FAILED;
         }
         requestUpdate();
@@ -164,9 +190,10 @@ void OtaUpdateActivity::loop() {
 
       {
         RenderLock lock(*this);
-        state = FINISHED;
+        state = UPDATE_IN_PROGRESS;
       }
       requestUpdate();
+      return;
     }
 
     if (mappedInput.wasPressed(MappedInputManager::Button::Back)) {
@@ -176,6 +203,46 @@ void OtaUpdateActivity::loop() {
     return;
   }
 
+  if (state == UPDATE_IN_PROGRESS) {
+    if (mappedInput.wasPressed(MappedInputManager::Button::Back)) {
+      updater.cancelUpdate();
+      finish();
+      return;
+    }
+
+    const auto res = updater.performInstallUpdateStep();
+    if (res == OtaUpdater::UPDATE_IN_PROGRESS) {
+      if (updater.getRender()) {
+        requestUpdate();
+        updater.clearRender();
+      }
+      return;
+    }
+
+    if (res == OtaUpdater::OK) {
+      {
+        RenderLock lock(*this);
+        state = FINISHED;
+      }
+      requestUpdate();
+      return;
+    }
+
+    if (res == OtaUpdater::UPDATE_CANCELLED) {
+      finish();
+      return;
+    }
+
+    LOG_DBG("OTA", "Update failed: %d", res);
+    {
+      RenderLock lock(*this);
+      failureReason = res;
+      state = FAILED;
+    }
+    requestUpdate();
+    return;
+  }
+
   if (state == FAILED) {
     if (mappedInput.wasPressed(MappedInputManager::Button::Back)) {
       finish();

src/activities/settings/OtaUpdateActivity.h

@@ -21,6 +21,7 @@ class OtaUpdateActivity : public Activity {
   State state = WIFI_SELECTION;
   unsigned int lastUpdaterPercentage = UNINITIALIZED_PERCENTAGE;
   OtaUpdater updater;
+  OtaUpdater::OtaUpdaterError failureReason = OtaUpdater::OK;
 
   void onWifiSelectionComplete(bool success);
 

src/main.cpp

@@ -13,6 +13,7 @@
 #include <Logging.h>
 #include <SPI.h>
 #include <builtinFonts/all.h>
+#include <esp_ota_ops.h>
 
 #include <cstring>
 
@@ -180,6 +181,13 @@ void setupDisplayAndFonts() {
 }
 
 void setup() {
+  {
+    esp_ota_img_states_t otaState;
+    const esp_partition_t* running = esp_ota_get_running_partition();
+    if (esp_ota_get_state_partition(running, &otaState) == ESP_OK && otaState == ESP_OTA_IMG_PENDING_VERIFY) {
+      esp_ota_mark_app_valid_cancel_rollback();
+    }
+  }
   HalSystem::begin();
   gpio.begin();
   powerManager.begin();

src/network/OtaUpdater.cpp

@@ -3,8 +3,12 @@
 #include <ArduinoJson.h>
 #include <Logging.h>
 
+#include "bootloader_common.h"
+#include "esp_flash_partitions.h"
 #include "esp_http_client.h"
 #include "esp_https_ota.h"
+#include "esp_ota_ops.h"
+#include "esp_partition.h"
 #include "esp_wifi.h"
 
 namespace {
@@ -28,45 +32,41 @@ esp_err_t http_client_set_header_cb(esp_http_client_handle_t http_client) {
 }
 
 esp_err_t event_handler(esp_http_client_event_t* event) {
-  /* We do interested in only HTTP_EVENT_ON_DATA event only */
+  /* We are only interested in HTTP_EVENT_ON_DATA event */
   if (event->event_id != HTTP_EVENT_ON_DATA) return ESP_OK;
 
-  if (!esp_http_client_is_chunked_response(event->client)) {
+  if (event->data == nullptr || event->data_len == 0) {
-    int content_len = esp_http_client_get_content_length(event->client);
+    return ESP_OK;
-    int copy_len = 0;
-
-    if (local_buf == NULL) {
-      /* local_buf life span is tracked by caller checkForUpdate */
-      local_buf = static_cast<char*>(calloc(content_len + 1, sizeof(char)));
-      output_len = 0;
-      if (local_buf == NULL) {
-        LOG_ERR("OTA", "HTTP Client Out of Memory Failed, Allocation %d", content_len);
-        return ESP_ERR_NO_MEM;
-      }
-    }
-    copy_len = min(event->data_len, (content_len - output_len));
-    if (copy_len) {
-      memcpy(local_buf + output_len, event->data, copy_len);
-    }
-    output_len += copy_len;
-  } else {
-    /* Code might be hits here, It happened once (for version checking) but I need more logs to handle that */
-    int chunked_len;
-    esp_http_client_get_chunk_length(event->client, &chunked_len);
-    LOG_DBG("OTA", "esp_http_client_is_chunked_response failed, chunked_len: %d", chunked_len);
   }
 
+  const int newSize = output_len + event->data_len + 1;
+  char* newBuf = static_cast<char*>(realloc(local_buf, static_cast<size_t>(newSize)));
+  if (newBuf == nullptr) {
+    LOG_ERR("OTA", "HTTP Client Out of Memory Failed, Allocation %d", newSize);
+    return ESP_ERR_NO_MEM;
+  }
+
+  local_buf = newBuf;
+  memcpy(local_buf + output_len, event->data, event->data_len);
+  output_len += event->data_len;
+  local_buf[output_len] = '\0';
+
   return ESP_OK;
 } /* event_handler */
 } /* namespace */
 
 OtaUpdater::OtaUpdaterError OtaUpdater::checkForUpdate() {
+  // Reset globals so retries start clean regardless of previous outcome
+  local_buf = nullptr;
+  output_len = 0;
+
   JsonDocument filter;
   esp_err_t esp_err;
   JsonDocument doc;
 
   esp_http_client_config_t client_config = {
       .url = latestReleaseUrl,
+      .timeout_ms = 10000,
       .event_handler = event_handler,
       /* Default HTTP client buffer size 512 byte only */
       .buffer_size = 8192,
@@ -199,28 +199,41 @@ bool OtaUpdater::isUpdateNewer() const {
 
 const std::string& OtaUpdater::getLatestVersion() const { return latestVersion; }
 
-OtaUpdater::OtaUpdaterError OtaUpdater::installUpdate() {
+void OtaUpdater::cleanupUpdate() {
+  if (otaHandle) {
+    const esp_err_t err = esp_https_ota_finish(otaHandle);
+    if (err != ESP_OK) {
+      LOG_ERR("OTA", "esp_https_ota_finish on cleanup: %s", esp_err_to_name(err));
+    }
+    otaHandle = nullptr;
+  }
+  cancelRequested = false;
+  esp_wifi_set_ps(WIFI_PS_MIN_MODEM);
+}
+
+void OtaUpdater::cancelUpdate() {
+  if (otaHandle) {
+    cleanupUpdate();
+  } else {
+    cancelRequested = true;
+  }
+}
+
+OtaUpdater::OtaUpdaterError OtaUpdater::beginInstallUpdate() {
   if (!isUpdateNewer()) {
     return UPDATE_OLDER_ERROR;
   }
 
-  esp_https_ota_handle_t ota_handle = NULL;
+  cleanupUpdate();
-  esp_err_t esp_err;
-  /* Signal for OtaUpdateActivity */
   render = false;
+  cancelRequested = false;
 
   esp_http_client_config_t client_config = {
       .url = otaUrl.c_str(),
-      .timeout_ms = 30000,
+      .timeout_ms = 10000,
-      /* Default HTTP client buffer size 512 byte only
-       * not sufficient to handle URL redirection cases or
-       * parsing of large HTTP headers.
-       */
       .max_redirection_count = 5,
       .buffer_size = 8192,
       .buffer_size_tx = 8192,
-      /* GitHub release assets redirect to objects.githubusercontent.com CDN.
-       * Without max_redirection_count, esp_https_ota downloads 0 bytes and stalls. */
       .crt_bundle_attach = esp_crt_bundle_attach,
       .keep_alive_enable = true,
   };
@@ -233,38 +246,122 @@ OtaUpdater::OtaUpdaterError OtaUpdater::installUpdate() {
   /* For better timing and connectivity, we disable power saving for WiFi */
   esp_wifi_set_ps(WIFI_PS_NONE);
 
-  esp_err = esp_https_ota_begin(&ota_config, &ota_handle);
+  esp_err_t esp_err = esp_https_ota_begin(&ota_config, &otaHandle);
   if (esp_err != ESP_OK) {
     LOG_DBG("OTA", "HTTP OTA Begin Failed: %s", esp_err_to_name(esp_err));
+    cleanupUpdate();
     return INTERNAL_UPDATE_ERROR;
   }
 
-  do {
+  return UPDATE_IN_PROGRESS;
-    esp_err = esp_https_ota_perform(ota_handle);
+}
-    processedSize = esp_https_ota_get_image_len_read(ota_handle);
+
-    /* Sent signal to  OtaUpdateActivity */
+/* Writes the otadata entry to boot from the most recently flashed OTA partition,
-    render = true;
+ * bypassing esp_ota_set_boot_partition()'s image_validate() call.
-    delay(100);  // TODO: should we replace this with something better?
+ * Used when esp_https_ota_finish() returns ESP_ERR_OTA_VALIDATE_FAILED on
-  } while (esp_err == ESP_ERR_HTTPS_OTA_IN_PROGRESS);
+ * unsigned Arduino builds (boot_comm efuse revision check false-positive). */
+int OtaUpdater::forceSetOtaBootPartition() {
+  const esp_partition_t* newPartition = esp_ota_get_next_update_partition(nullptr);
+  if (newPartition == nullptr) {
+    return ESP_ERR_NOT_FOUND;
+  }
+
+  const esp_partition_t* otaDataPartition =
+      esp_partition_find_first(ESP_PARTITION_TYPE_DATA, ESP_PARTITION_SUBTYPE_DATA_OTA, nullptr);
+  if (otaDataPartition == nullptr) {
+    return ESP_ERR_NOT_FOUND;
+  }
+
+  esp_ota_select_entry_t otadata[2];
+  esp_err_t err = esp_partition_read(otaDataPartition, 0, &otadata[0], sizeof(esp_ota_select_entry_t));
+  if (err != ESP_OK) return err;
+  err = esp_partition_read(otaDataPartition, otaDataPartition->erase_size, &otadata[1], sizeof(esp_ota_select_entry_t));
+  if (err != ESP_OK) return err;
+
+  int activeSlot = bootloader_common_get_active_otadata(otadata);
+  int nextSlot = (activeSlot == -1) ? 0 : (~activeSlot & 1);
+
+  uint8_t otaAppCount = 0;
+  while (esp_partition_find_first(ESP_PARTITION_TYPE_APP,
+                                  static_cast<esp_partition_subtype_t>(ESP_PARTITION_SUBTYPE_APP_OTA_MIN + otaAppCount),
+                                  nullptr) != nullptr) {
+    otaAppCount++;
+  }
+  if (otaAppCount == 0) return ESP_ERR_NOT_FOUND;
+
+  const uint8_t subTypeId = newPartition->subtype & 0x0F;
+  uint32_t newSeq;
+  if (activeSlot == -1) {
+    newSeq = subTypeId + 1;
+  } else {
+    uint32_t currentSeq = otadata[activeSlot].ota_seq;
+    newSeq = currentSeq;
+    while (newSeq % otaAppCount != static_cast<uint32_t>(subTypeId)) {
+      newSeq++;
+    }
+    if (newSeq == currentSeq) newSeq += otaAppCount;
+  }
+
+  otadata[nextSlot].ota_seq = newSeq;
+  otadata[nextSlot].ota_state = ESP_OTA_IMG_VALID;
+  otadata[nextSlot].crc = bootloader_common_ota_select_crc(&otadata[nextSlot]);
+
+  err = esp_partition_erase_range(otaDataPartition, otaDataPartition->erase_size * static_cast<uint32_t>(nextSlot),
+                                  otaDataPartition->erase_size);
+  if (err != ESP_OK) return err;
+
+  return esp_partition_write(otaDataPartition, otaDataPartition->erase_size * static_cast<uint32_t>(nextSlot),
+                             &otadata[nextSlot], sizeof(esp_ota_select_entry_t));
+}
+
+OtaUpdater::OtaUpdaterError OtaUpdater::performInstallUpdateStep() {
+  if (cancelRequested) {
+    cleanupUpdate();
+    return UPDATE_CANCELLED;
+  }
+
+  if (!otaHandle) {
+    return INTERNAL_UPDATE_ERROR;
+  }
+
+  esp_err_t esp_err = esp_https_ota_perform(otaHandle);
+  processedSize = esp_https_ota_get_image_len_read(otaHandle);
+  render = true;
+
+  if (esp_err == ESP_ERR_HTTPS_OTA_IN_PROGRESS) {
+    return UPDATE_IN_PROGRESS;
+  }
 
-  /* Return back to default power saving for WiFi in case of failing */
   esp_wifi_set_ps(WIFI_PS_MIN_MODEM);
 
   if (esp_err != ESP_OK) {
     LOG_ERR("OTA", "esp_https_ota_perform Failed: %s", esp_err_to_name(esp_err));
-    esp_https_ota_finish(ota_handle);
+    cleanupUpdate();
     return HTTP_ERROR;
   }
 
-  if (!esp_https_ota_is_complete_data_received(ota_handle)) {
+  if (!esp_https_ota_is_complete_data_received(otaHandle)) {
-    LOG_ERR("OTA", "esp_https_ota_is_complete_data_received Failed: %s", esp_err_to_name(esp_err));
+    LOG_ERR("OTA", "esp_https_ota_is_complete_data_received Failed");
-    esp_https_ota_finish(ota_handle);
+    cleanupUpdate();
     return INTERNAL_UPDATE_ERROR;
   }
 
-  esp_err = esp_https_ota_finish(ota_handle);
+  esp_err_t finish_err = esp_https_ota_finish(otaHandle);
-  if (esp_err != ESP_OK) {
+  otaHandle = nullptr;
-    LOG_ERR("OTA", "esp_https_ota_finish Failed: %s", esp_err_to_name(esp_err));
+  if (finish_err == ESP_ERR_OTA_VALIDATE_FAILED) {
+    /* Arduino unsigned builds fail boot_comm validation even though the image
+     * is fully written. Force the boot partition to the new OTA slot by writing
+     * the otadata entry directly, bypassing image_validate(). */
+    LOG_INF("OTA", "Validation failed (expected for unsigned Arduino builds) - forcing boot partition");
+    finish_err = forceSetOtaBootPartition();
+    if (finish_err != ESP_OK) {
+      LOG_ERR("OTA", "forceSetOtaBootPartition failed: %s", esp_err_to_name(finish_err));
+      cleanupUpdate();
+      return VALIDATE_FAILED;
+    }
+  } else if (finish_err != ESP_OK) {
+    LOG_ERR("OTA", "esp_https_ota_finish Failed: %s", esp_err_to_name(finish_err));
+    cleanupUpdate();
     return INTERNAL_UPDATE_ERROR;
   }
 

src/network/OtaUpdater.h

@@ -3,6 +3,10 @@
 #include <functional>
 #include <string>
 
+// Avoid pulling in esp_https_ota.h here — it transitively includes lwip/sockets.h
+// which defines INADDR_NONE as a numeric macro, conflicting with Arduino's IPAddress.h.
+typedef void* esp_https_ota_handle_t;
+
 class OtaUpdater {
   bool updateAvailable = false;
   std::string latestVersion;
@@ -11,6 +15,8 @@ class OtaUpdater {
   size_t processedSize = 0;
   size_t totalSize = 0;
   bool render = false;
+  esp_https_ota_handle_t otaHandle = nullptr;
+  bool cancelRequested = false;
 
  public:
   enum OtaUpdaterError {
@@ -21,6 +27,9 @@ class OtaUpdater {
     UPDATE_OLDER_ERROR,
     INTERNAL_UPDATE_ERROR,
     OOM_ERROR,
+    UPDATE_CANCELLED,
+    UPDATE_IN_PROGRESS,
+    VALIDATE_FAILED,
   };
 
   size_t getOtaSize() const { return otaSize; }
@@ -30,10 +39,19 @@ class OtaUpdater {
   size_t getTotalSize() const { return totalSize; }
 
   bool getRender() const { return render; }
+  void clearRender() { render = false; }
+
+  bool isUpdateInProgress() const { return otaHandle != nullptr; }
 
   OtaUpdater() = default;
   bool isUpdateNewer() const;
   const std::string& getLatestVersion() const;
   OtaUpdaterError checkForUpdate();
-  OtaUpdaterError installUpdate();
+  OtaUpdaterError beginInstallUpdate();
+  OtaUpdaterError performInstallUpdateStep();
+  void cancelUpdate();
+  void cleanupUpdate();
+
+ private:
+  static int forceSetOtaBootPartition();
 };