forgefirm/docs/UPDATE-SYSTEM.md

ForgeFIRM install, update & recovery system — implementation plan

Phased plan for moving ForgeFIRM from the legacy carve-out-a-partition install to the factory's own A/B slot scheme, with signed .fw packaging, a GUI update manager, factory restore, and a refreshed recovery image. The measured ground truth this builds on (eMMC layout, boot0/boot1 maps, saved-env location, factory .fw/updater internals) is in BRINGUP.md → "eMMC boot & recovery architecture".

Settled decisions

• Factory partition scheme, unmodified: ForgeFIRM lives in the two 200 MiB rootfs slots (mmcblk2p1/p2); /data (p3) keeps its full factory size. No repartitioning at install, ever.
• Single-OS, not dual-boot: a machine runs ForgeFIRM or factory firmware, with a clean migration each way. The factory updater's behavior toward foreign slot contents is irrelevant because we never operate both long-term.
• fwup is the universal package/apply format (the factory's own mechanism): ForgeFIRM upgrades, factory restore, and provisioning all use signed .fw archives applied to the inactive slot, followed by a U-Boot env flip — exactly the factory update flow.
• Factory firmware is archived to /data before any factory slot is overwritten. Restore-to-factory never depends on Glowforge's servers; the cloud path (GET /update/current, already implemented in gfutilities) is the optional "restore to latest" upgrade.
• Release artifacts are built and signed locally, uploaded as GitHub releases. The Ed25519 private key never leaves the build host, so GitHub is untrusted hosting: machines verify signatures before applying. CI does compile checks only, never artifacts.
• Reinstalling ForgeFIRM from factory = run the installer again, until the recovery refresh (Phase 5) subsumes it.
• Recovery refresh is squashfs-only in v1: factory U-Boot, DTB and the 3.14.28 recovery kernel stay in place; only the recovery userspace is replaced.

Invariants (every flash path, every phase)

1. Never write the active (running) slot.
2. Machine idle; one flash operation at a time (lock file); no flash/reboot while a job runs.
3. Archive factory content before the write that would destroy the last copy of it (rootfs slots; boot0/boot1 before a recovery refresh).
4. Env flips are atomic: one fw_setenv -s transaction setting all four of mmcdev/mmchwpart/mmcpart/mmcroot.
5. Automatic paths (release updater, cloud restore) require a valid signature — ours or Glowforge's respectively. Manual uploads may be unsigned behind an explicit "unsigned dev image" warning.
6. The image must fit the 200 MiB slot; the build fails past the size gate rather than producing an unflashable release.
7. Boot selection refuses targets that fail the content probe (no kernel / no recognizable rootfs).
8. Verify a written slot (fwup on-the-fly hashes, or an explicit readback/mount check for raw writes) before flipping boot to it.

Phase 0 — enablers (no eMMC flashing)

• 0.1 Slot-agnostic images. Goal: one image boots unmodified from p1, p2, or SD, steered only by the saved env (U-Boot's mmcargs already takes root=${mmcroot} from the env). Audit what our /boot/uEnv.txt currently sets; strip it to entries that are not per-location (fdt_file etc.); bench-verify by flipping env alone. This removes the mount-and-sed step from every flash path. Exit: the same built image boots from two locations with no per-slot edit.
• 0.2 fwup toolchain + keys. Yocto recipe for fwup (target) and a host-side pack step. Generate the ForgeFIRM Ed25519 keypair (custody: offline on the build host, passphrase-protected, backed up). Compatibility gates, both directions: (a) a .fw we pack must apply with the factory's fwup 0.14.2 (the installer runs on factory firmware; fall back to shipping a static armv7 fwup with the installer if archive-format drift bites), and (b) our shipped fwup must apply a factory .fw verified against the GF pubkeys (carried from the factory image) for cloud restore.
• 0.3 Build outputs. forgefirm-image additionally emits the raw ext4 rootfs and a packed+signed forgefirm-<ver>.fw with upgrade.a / upgrade.b tasks in the factory pattern (partition-relative raw writes, unmounted-destination + on-the-fly-verify options); size gate enforced here. A complete full-provisioning task joins with the Phase 5 recovery work. The wic stays for SD/dev burns.

Phase 1 — ffboot v2 + slot probe

• Atomic env flip (invariant 4) — fixes the existing gaps: three separate fw_setenv calls today, and mmchwpart never set (relies on the saved 0).
• ffboot -l (or a sibling tool): inventory every candidate — eMMC p1/p2, legacy p4, SD — by read-only mount: factory /etc/version or /etc/forgefirm-version, kernel presence; plus the current env selection. Machine-parsable output; this is the probe the GUI and the installer both reuse.
• Exit: bench-verified flips SD ↔ eMMC slots; inventory correct for factory / ForgeFIRM / empty slots.

Phase 2 — slot installer (factory → ForgeFIRM)

Rewrite install-forgefirm.sh as a single-stage script run from factory firmware:

1. Sanity: factory 3-partition layout, both slots 200 MiB, active slot detected (rdev), enough /data space.
2. Archive: every factory slot version not already archived — dd | gzip to /data/forgefirm/archive/factory-rootfs-<ver>.img.gz with a manifest line (slot, version, date, md5); also dump boot0/boot1 (32 MiB) into the archive now, ahead of Phase 5. With both slots archived, any later overwrite needs no second archive step.
3. Fetch forgefirm.fw from GitHub releases (fixed asset name — the releases/latest/download/ URL needs one; the version lives in the fwup metadata and the release tag), or take a local file argument for offline/dev installs. Verify the signature against the ForgeFIRM pubkey embedded in the installer (raw 32-byte form for the factory's fwup; a dev key until the production ceremony).
4. Apply to the inactive slot (fwup + our pubkey). The booted factory install stays bootable in the other slot.
5. Atomic env flip (embed the flip logic — the factory rootfs has no ffboot v2), reboot.

No repartitioning, no /data backup/restore dance, no stage 2. Rewrite INSTALL.md accordingly (serial console procedure stays).

Exit: a factory machine converts in one pass; ffboot returns it to the intact factory slot; /data (calibration, credentials, logs) demonstrably untouched.

Phase 2b — legacy p4 migration

• Boot-time init script (before /data mounts), gated on: booted from mmcblk2p1/p2 (never SD, never p4) AND legacy geometry present (p4 exists, or p3 ends short of the disk). Actions: delete p4, extend p3's end to the disk (starts unchanged), resize2fs. Idempotent and power-safe: every step keyed off actual disk state, re-runnable after interruption.
• Existing p4 users reach the new scheme by running the new installer from their running ForgeFIRM (same flow as Phase 2; both factory slots intact → archive newer, overwrite older), then the boot-time check reclaims p4/p3 on first slot boot.
• Exit: a legacy-layout machine migrates with /data contents intact and grown to full size; re-boot is a no-op.

Phase 3 — release pipeline

• scripts/release.sh (build host): gates → kas build → pack .fw → sign → sha256sums.txt → staged assets + gh release create command (--publish runs it where gh is authenticated). Gates: clean tree, version single-source, rootfs-vs-slot size (warn ≥ 170 MiB / fail ≥ 195 MiB, under bitbake's own hard cap), installer-embedded pubkey must match the signing key, and factory-era fwup (0.14.2) verification of the packed archive.
• One version source: FORGEFIRM_RELEASE = git tag = /etc/forgefirm-version = .fw meta-version; the script enforces agreement.
• release.sh --dev packs a dev-key-signed forgefirm-dev.fw from the release rootfs for the GUI upload path (decides open question 4: dev archives are signed with the dev key, never unsigned — the GUI exercises the same verification path either way).
• GitHub Actions: per-push compile checks for grblHAL-glowforge and forgectrl (minutes, no Yocto); optional workflow_dispatch cold-Yocto reproducibility build whose only product is a checksum.

Phase 4 — forgectrl update manager (GUI)

Backend endpoints + a panel page (OpenGlow visual identity):

• Inventory: slot contents (Phase 1 probe), current/next boot selection, archive presence/version.
• Update check against the GitHub releases API (manual button + periodic while idle; offline-tolerant, rate-limit friendly).
• Apply release: download .fw to /data, verify signature, apply to inactive slot, verify, then flip only on explicit user confirmation, prompt reboot.
• Upload: streamed multipart to /data (never RAM-buffered); accepts .fw (verify; warn if unsigned) and .wic.gz/.ext4.gz (dev; size + superblock sanity checks).
• Boot selector incl. SD, with warnings — most prominently on switch-to-factory: the factory updater may auto-update and overwrite the other slot. Refuses unprobeable targets.
• Factory restore: from the /data archive (offline) or cloud latest (gfutilities device auth → GF-signed .fw → verify with GF pubkeys) → inactive slot → flip. Optional cleanup of ForgeFIRM residue in /data for true factory condition.
• Interlocks throughout: idle-only, update lock, never the active slot, rollback = flip back to the previous slot.

Exit: full loop on the bench — GUI upgrade, rollback via boot selector, factory restore and return — without touching a shell.

Phase 5 — recovery refresh (reserved; build after 0–4 land)

• v1 scope: replace only the boot0 recovery squashfs (boot1 /usr only if needed). Never write below offset 0xC0000 in boot0 — U-Boot is physically untouchable by the refresh tool. Factory DTB and kernel 3.14.28 stay.
• Userspace: static busybox + fwup + a small C webapp (ulfius) + hostapd/wpa_supplicant. No Python. Must carry 3.14.28-matched WiFi modules (decision gate: lift from the factory recovery vs rebuild from Glowforge's published GPL kernel source).
• Functions: button-hold → AP + web UI (factory UX): upload a .fw (verified against our and GF pubkeys — either firmware installable), install from the /data archive, set boot target, export logs.
• Flash tool: boot0/boot1 archived first (Phase 2 already does), force_ro unlock, write high regions only, readback verify; if both partitions are written, boot1 first, boot0 last.
• First flashes bench-gated on an attached serial console.
• Documented recovery ladder from then on: other slot → button-hold recovery → SD card → serial console.

Contracts

• Artifacts (consumers: installer, GUI updater, recovery): forgefirm.fw (fixed asset name; signed; version in the fwup metadata = release tag v<semver>; tasks upgrade.a/upgrade.b, complete from Phase 5), sha256sums.txt, forgefirm-image-glowforge.rootfs.wic.gz (SD burns).
• Env: SD = 0/0/1//dev/mmcblk1p1; slot N = 1/0/N//dev/mmcblk2pN (mmcdev/mmchwpart/mmcpart/mmcroot, always one transaction).
• Archive layout: /data/forgefirm/archive/ — factory-rootfs-<ver>.img.gz, boot0.img, boot1.img, manifest (slot versions, dates, checksums).

Open questions / decision gates

1. Exact minimal uEnv.txt contents (Phase 0.1 spike decides).
2. fwup archive compatibility with the factory 0.14.2 binary — else ship a static fwup alongside the installer.
3. Size-gate thresholds (proposal: warn > 170 MiB, fail > 190 MiB image vs the ~195 MiB usable slot).
4. Dev-image signing policy: dedicated dev key vs unsigned-with-warning only.
5. Periodic GUI update check default-on vs opt-in (it pings the GitHub API; proposal: on by default, apply always manual, config switch to disable).
6. Recovery kernel modules: carried from the factory image vs rebuilt from GPL source (Phase 5 gate).
7. U-Boot bootcount/auto-revert: out of scope — the recovery ladder covers bad flips; revisit only if field incidents say otherwise.

Sequencing

0 → 1 → 2 + 2b → 3 → 4 → 5, strictly: everything after Phase 0 assumes slot-agnostic images and working .fw round-trips; the GUI (4) reuses the probe (1) and pipeline (3); recovery (5) is an independent mini-project once the slot scheme is provenly stable. First user-visible milestone is after Phase 2: a converted machine with instant offline factory switchback.