IoT Sensor Gateway Firmware v1.0.6

Release v1.0.5 - Enhanced Packet Validation & Emergency Protection

🚀 New Features

Emergency Shutdown System

• Automatic protection against broker flooding with invalid packet detection
• WiFi credential clearing instead of complete shutdown for easier recovery
• AP mode fallback - device becomes configurable after emergency shutdown
• Rate limiting - max 1000 packets/minute to prevent excessive processing

Enhanced Packet Validation

• Comprehensive validation - checks for zero values, FF corruption, unrealistic readings
• Detailed error reporting - shows exactly why packets are rejected in debug mode
• Fixed packet counting - now correctly counts 9-byte packets instead of individual bytes
• Packet statistics - tracks total bytes vs packets, invalid ratios, and rate limits

Debug Mode

• Remote serial output - capture device logs via MQTT diagnostics
• Real-time monitoring - see packet processing, validation errors, and system status
• Configurable logging - enable/disable debug mode remotely

Certificate Management

• OTA certificate updates - update certificates via MQTT without firmware recompile
• Certificate rotation - reset to embedded certificates or update to new ones
• Fallback protection - uses embedded certificates if preferences are empty

🔧 Improvements

WiFi Configuration

• Extended AP timeout - increased from 2 minutes to 15 minutes for easier setup
• Better error handling - improved WiFi connection diagnostics
• Cleaner AP mode - proper WiFi mode switching and disconnection

MQTT Reliability

• Automatic reconnection - handles connection drops gracefully
• Enhanced diagnostics - detailed connection and packet statistics
• Emergency alerts - immediate notification of critical issues

Sensor Data Management

• Cache size limits - prevents memory overflow with large sensor counts
• Automatic cleanup - removes oldest sensors when cache is full
• Better validation - filters out corrupted or unrealistic sensor readings

🛡️ Security & Stability

Rate Limiting

• Packet rate limits - prevents processing more than 1000 packets/minute
• Invalid packet limits - stops processing if >500 invalid packets/minute
• Emergency shutdown - triggers at 80% invalid packet ratio

Recovery Options

• Remote reset - clear statistics and recover from emergency shutdown
• Firmware updates - OTA updates with improved error handling
• Configuration reset - clear WiFi credentials and restart in AP mode

📊 New Commands

// Enable debug mode
{"action": "debug_mode", "enabled": true}

// Reset packet statistics
{"action": "reset_stats"}

// Update certificates
{"action": "update_certificates", "rootca": "...", "devicecert": "...", "privatekey": "..."}

// Reset to embedded certificates
{"action": "reset_certificates"}

// Manual emergency shutdown
{"action": "emergency_shutdown", "enabled": true}

🔍 Diagnostics

Enhanced diagnostics now include:

• Packet statistics - total bytes, packets, invalid counts, rates
• Emergency status - shutdown state and reasons
• Connection health - WiFi signal, uptime, readings sent
• Debug output - serial logs when debug mode is enabled

🐛 Bug Fixes

• Fixed packet counting - now correctly counts 9-byte packets instead of individual bytes
• Improved UART handling - better noise filtering and packet validation
• Memory management - prevents sensor cache overflow
• WiFi reconnection - more reliable connection recovery

📈 Performance

• Reduced memory usage - efficient packet processing and validation
• Faster startup - optimized WiFi connection and certificate loading
• Better error recovery - graceful handling of corrupted data and connection issues

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Upgrade Instructions:

1. Send firmware update command with v1.0.5 binary URL
2. Device will automatically update and restart
3. Monitor diagnostics for proper operation
4. Enable debug mode if needed for troubleshooting

Compatibility: ESP32-C6, Arduino IDE 2.0+, ESP32 Arduino Core 2.0+