Add unified OTA capability for edge_agent (SD + HTTP)

application/edge_agent/main/CMakeLists.txt

@@ -1,6 +1,7 @@
 set(main_requires
     app_claw
     app_config
+    app_ota
     captive_dns
     http_server
     wifi_manager

application/edge_agent/main/idf_component.yml

@@ -24,6 +24,9 @@ dependencies:
   app_config:
     path: ../components/app_config
 
+  app_ota:
+    path: ../../../components/common/app_ota
+
   cap_im_wechat:
     path: ../../../components/claw_capabilities/cap_im_wechat
     rules:

application/edge_agent/main/main.c

@@ -19,6 +19,7 @@
 #include "esp_board_manager_includes.h"
 #include "captive_dns.h"
 #include "cmd_wifi.h"
+#include "app_ota.h"
 #include "freertos/FreeRTOS.h"
 #include "freertos/task.h"
 #if CONFIG_APP_CLAW_CAP_IM_WECHAT
@@ -325,7 +326,24 @@ void app_main(void)
     init_timezone(app_config_get_timezone(s_config)); // no need to check error
     ESP_ERROR_CHECK(esp_board_manager_init());
     ESP_ERROR_CHECK(app_claw_ui_start());
+#if CONFIG_APP_OTA_FS_ENABLE && CONFIG_APP_OTA_FS_TRY_SDCARD_AT_BOOT && CONFIG_APP_OTA_FS_RUN_AT_BOOT
+    {
+        esp_err_t ota_sd_err =
+            app_ota_fs_boot_flow_at(CONFIG_APP_OTA_FS_SDCARD_FIRMWARE_ABS_PATH);
+        if (ota_sd_err != ESP_OK) {
+            ESP_LOGW(TAG, "SD FS OTA: %s", esp_err_to_name(ota_sd_err));
+        }
+    }
+#endif
     ESP_ERROR_CHECK(init_fatfs());
+#if CONFIG_APP_OTA_FS_ENABLE
+    {
+        esp_err_t ota_fs_err = app_ota_fs_boot_flow();
+        if (ota_fs_err != ESP_OK) {
+            ESP_LOGW(TAG, "FS OTA: %s", esp_err_to_name(ota_fs_err));
+        }
+    }
+#endif
     ESP_ERROR_CHECK(wifi_manager_init());
     ESP_ERROR_CHECK(http_server_init(&(http_server_config_t) {
         .storage_base_path = app_fatfs_base_path,
@@ -378,6 +396,15 @@ void app_main(void)
                  status.ap_ip);
     }
 
+    {
+        wifi_manager_status_t wm_ota = {0};
+        wifi_manager_get_status(&wm_ota);
+        esp_err_t ota_err = app_ota_http_boot_flow(wm_ota.sta_connected);
+        if (ota_err != ESP_OK) {
+            ESP_LOGW(TAG, "OTA bootstrap: %s", esp_err_to_name(ota_err));
+        }
+    }
+
     ESP_ERROR_CHECK(app_claw_init_storage_paths(s_claw_paths));
     ESP_ERROR_CHECK(app_claw_start(s_claw_config, s_claw_paths));
 #if CONFIG_APP_CLAW_CAP_IM_LOCAL

application/edge_agent/partitions_8MB.csv

@@ -2,6 +2,9 @@
 nvs,       data, nvs,     0x9000,   0x6000
 otadata,   data, ota,     0xF000,   0x2000
 phy_init,  data, phy,     0x11000,  0x1000
-ota_0,     app,  ota_0,         ,   3M
-emote,     data, spiffs,        ,   3M
-storage,   data, fat,           ,  1500K
+# OTA slots slightly larger than 2560K for edge_agent ~0x288210 (tools/ota_sdcard_hil builds fat claw).
+# Keep total app+emote+storage = 8064K like older layout; shrink emote when HIL disables APP_CLAW_ENABLE_EMOTE (see ota_sdcard_hil.py overlay).
+ota_0,     app,  ota_0,         ,   2624K
+ota_1,     app,  ota_1,         ,   2624K
+emote,     data, spiffs,        ,   1792K
+storage,   data, fat,           ,   1024K

application/edge_agent/sdkconfig.defaults

@@ -1,6 +1,8 @@
 # This file was generated using idf.py save-defconfig. It can be edited manually.
 # Espressif IoT Development Framework (ESP-IDF) 5.5.1 Project Minimal Configuration
 #
+# Match on-module flash and partitions_8MB.csv (overrides board_manager 2MB default for HIL / fresh sdkconfig)
+CONFIG_ESPTOOLPY_FLASHSIZE_8MB=y
 CONFIG_PARTITION_TABLE_CUSTOM=y
 CONFIG_PARTITION_TABLE_CUSTOM_FILENAME="partitions_8MB.csv"
 CONFIG_HTTPD_WS_SUPPORT=y

components/common/app_claw/app_claw_cli.c

@@ -740,6 +740,7 @@ esp_err_t app_claw_cli_start(void)
 {
     esp_console_repl_t *repl = NULL;
     esp_console_repl_config_t repl_config = ESP_CONSOLE_REPL_CONFIG_DEFAULT();
+    esp_err_t err = ESP_OK;
 
     ESP_LOGI(TAG, "Starting console REPL");
 
@@ -749,18 +750,22 @@ esp_err_t app_claw_cli_start(void)
 
 #if CONFIG_ESP_CONSOLE_UART_DEFAULT || CONFIG_ESP_CONSOLE_UART_CUSTOM
     esp_console_dev_uart_config_t hw_config = ESP_CONSOLE_DEV_UART_CONFIG_DEFAULT();
-    ESP_ERROR_CHECK(esp_console_new_repl_uart(&hw_config, &repl_config, &repl));
+    err = esp_console_new_repl_uart(&hw_config, &repl_config, &repl);
 #elif CONFIG_ESP_CONSOLE_USB_SERIAL_JTAG
     esp_console_dev_usb_serial_jtag_config_t hw_config =
         ESP_CONSOLE_DEV_USB_SERIAL_JTAG_CONFIG_DEFAULT();
-    ESP_ERROR_CHECK(esp_console_new_repl_usb_serial_jtag(&hw_config, &repl_config, &repl));
+    err = esp_console_new_repl_usb_serial_jtag(&hw_config, &repl_config, &repl);
 #elif CONFIG_ESP_CONSOLE_USB_CDC
     esp_console_dev_usb_cdc_config_t hw_config = ESP_CONSOLE_DEV_CDC_CONFIG_DEFAULT();
-    ESP_ERROR_CHECK(esp_console_new_repl_usb_cdc(&hw_config, &repl_config, &repl));
+    err = esp_console_new_repl_usb_cdc(&hw_config, &repl_config, &repl);
 #else
     ESP_LOGE(TAG, "No supported console backend is enabled");
     return ESP_ERR_NOT_SUPPORTED;
 #endif
+    if (err != ESP_OK) {
+        ESP_LOGE(TAG, "Create REPL failed: %s", esp_err_to_name(err));
+        return err;
+    }
 
     esp_console_register_help_command();
     register_cap_cli_commands();
@@ -771,7 +776,11 @@ esp_err_t app_claw_cli_start(void)
             .help = "Submit a multi-turn prompt using the current session: ask <prompt>",
             .func = cmd_ask,
         };
-        ESP_ERROR_CHECK(esp_console_cmd_register(&ask_cmd));
+        err = esp_console_cmd_register(&ask_cmd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "Register 'ask' failed: %s", esp_err_to_name(err));
+            return err;
+        }
     }
 
     {
@@ -780,7 +789,11 @@ esp_err_t app_claw_cli_start(void)
             .help = "Submit a single-turn prompt without session history: ask_once <prompt>",
             .func = cmd_ask_once,
         };
-        ESP_ERROR_CHECK(esp_console_cmd_register(&ask_once_cmd));
+        err = esp_console_cmd_register(&ask_once_cmd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "Register 'ask_once' failed: %s", esp_err_to_name(err));
+            return err;
+        }
     }
 
     {
@@ -789,7 +802,11 @@ esp_err_t app_claw_cli_start(void)
             .help = "Show or switch the current session: session [id]",
             .func = cmd_session,
         };
-        ESP_ERROR_CHECK(esp_console_cmd_register(&session_cmd));
+        err = esp_console_cmd_register(&session_cmd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "Register 'session' failed: %s", esp_err_to_name(err));
+            return err;
+        }
     }
 
     {
@@ -798,7 +815,11 @@ esp_err_t app_claw_cli_start(void)
             .help = "cap operations: cap <list|call|groups|enable|disable|unload|load> ...",
             .func = cmd_cap,
         };
-        ESP_ERROR_CHECK(esp_console_cmd_register(&cap_cmd));
+        err = esp_console_cmd_register(&cap_cmd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "Register 'cap' failed: %s", esp_err_to_name(err));
+            return err;
+        }
     }
 
     {
@@ -807,7 +828,11 @@ esp_err_t app_claw_cli_start(void)
             .help = "Automation operations: auto <reload|rules|rule|add_rule|update_rule|delete_rule|last|emit_message|emit_trigger> ...",
             .func = cmd_auto,
         };
-        ESP_ERROR_CHECK(esp_console_cmd_register(&auto_cmd));
+        err = esp_console_cmd_register(&auto_cmd);
+        if (err != ESP_OK) {
+            ESP_LOGE(TAG, "Register 'auto' failed: %s", esp_err_to_name(err));
+            return err;
+        }
     }
 
     printf("Type 'help', 'auto rules', 'auto last', or 'auto emit_message qq_gateway qq 123 hello'\n");

components/common/app_ota/CMakeLists.txt

@@ -0,0 +1,8 @@
+idf_component_register(
+    SRCS
+        "app_ota.c"
+    INCLUDE_DIRS
+        "include"
+    REQUIRES
+        esp_ota_service
+)

components/common/app_ota/Kconfig

@@ -0,0 +1,94 @@
+menu "App OTA (esp_ota_service)"
+
+    menu "HTTP OTA bootstrap"
+
+        config APP_OTA_HTTP_ENABLE
+            bool "Enable optional HTTP firmware OTA bootstrap"
+            default n
+            help
+                When enabled and manifest/firmware URLs are non-empty (menuconfig below),
+                the device runs one HTTP OTA check after Wi‑Fi STA is connected during boot.
+
+        if APP_OTA_HTTP_ENABLE
+
+            config APP_OTA_HTTP_RUN_AT_BOOT
+                bool "Run HTTP OTA check once at startup (after STA online)"
+                default y
+
+            config APP_OTA_HTTP_MANIFEST_URL
+                string "Firmware manifest JSON URL (http/https)"
+                default ""
+                help
+                    JSON manifest consumed by esp_ota_service_checker_manifest (version, optional sha256, size).
+
+            config APP_OTA_HTTP_FIRMWARE_URL
+                string "Firmware binary URL (must match manifest server)"
+                default ""
+                help
+                    Absolute URL for the downloadable app image (paired with APP_OTA_HTTP_MANIFEST_URL).
+
+            config APP_OTA_HTTP_CHUNK_TIMEOUT_MS
+                int "HTTP read timeout per chunk (milliseconds)"
+                default 30000
+                range 3000 120000
+
+        endif # APP_OTA_HTTP_ENABLE
+
+    endmenu
+
+    menu "Filesystem OTA bootstrap"
+
+        config APP_OTA_FS_ENABLE
+            bool "Enable optional filesystem (VFS) app OTA bootstrap"
+            default y
+            help
+                After SPI flash FAT mounts (typically /fatfs), read a staged edge_agent.bin from an absolute path
+                using esp_ota_service_source_fs. Runs **before Wi-Fi**. File must expose a higher semver than running
+                image when APP_OTA_FS_REQUIRE_NEWER_SEMVER=y.
+
+        if APP_OTA_FS_ENABLE
+
+            config APP_OTA_FS_RUN_AT_BOOT
+                bool "Run FS OTA when candidate file exists at boot"
+                default y
+
+            config APP_OTA_FS_FIRMWARE_ABS_PATH
+                string "Absolute filesystem path (VFS fopen) for app binary"
+                default "/fatfs/ota/firmware.bin"
+                help
+                    Typical layout: mkdir /fatfs/ota via host mount and drop edge_agent.bin renamed to firmware.bin.
+
+            config APP_OTA_FS_TRY_SDCARD_AT_BOOT
+                bool "Before SPI flash FAT, try app OTA from SD (board_manager fs_sdcard)"
+                default n
+                help
+                    After esp_board_manager_init(), if the board exposes fs_sdcard (usually mounted at /sdcard),
+                    probe APP_OTA_FS_SDCARD_FIRMWARE_ABS_PATH for a newer app image.
+                    Matches esp_ota_service tools/sdcard_writer output name firmware.bin.
+                    Use together with tools/ota_sdcard_hil.py and ota_fs_flash_sdcard.py from ADF.
+
+            config APP_OTA_FS_SDCARD_FIRMWARE_ABS_PATH
+                string "Absolute path on SD mount for app binary"
+                default "/sdcard/firmware.bin"
+                depends on APP_OTA_FS_TRY_SDCARD_AT_BOOT
+                help
+                    Default matches sdcard_writer (components/esp_ota_service/tools/sdcard_writer).
+
+            config APP_OTA_FS_READ_BUF_BYTES
+                int "Read buffer chunk size passed to filesystem source"
+                default 4096
+                range 512 8192
+
+            config APP_OTA_FS_REQUIRE_NEWER_SEMVER
+                bool "Reject candidate whose esp_app_desc_t version is not strictly higher"
+                default y
+
+            config APP_OTA_FS_CHECK_PROJECT_NAME
+                bool "Reject candidate when esp_app_desc_t project_name differs from running firmware"
+                default y
+
+        endif # APP_OTA_FS_ENABLE
+
+    endmenu
+
+endmenu