IOTAfy: An ESP32-Based OTA Firmware Management Platform for Scalable IoT Deployments

Managing firmware updates in large-scale IoT deployments presents significant challenges regarding security, reliability, and operational cost. This paper presents the design and implementation of “IOTAfy”, a new, open-source, comprehensive, Over-The-Air (OTA) firmware management platform tailored for ESP32-based IoT devices. “IOTAfy” distinguishes itself through its efficient database design and asynchronous update mechanism, enabling scalable deployments. The proposed system comprises a device-side solution for ESP32 microcontrollers, incorporating a custom bootloader, an application firmware boilerplate code, and an OTA library, alongside a web-based management interface developed using PHP, SQLite3, and Bootstrap. This integrated approach facilitates secure and reliable OTA application firmware updates. The platform enables centralized monitoring of device status, scheduled firmware updates, and robust version control for multiple IoT devices. OTA updates are implemented directly on the ESP32, eliminating the need for physical access or intervention. The web interface provides administrators with features for group upgrades, rollback capabilities, real-time update status monitoring and alerts. The system was tested in a controlled environment with 50 ESP32 devices, achieving a 98% success rate for OTA updates. Results demonstrate the potential for significant cost savings and reduced maintenance time compared to manual update processes. The architecture of the “IOTAfy” platform, leveraging an efficient database design and asynchronous update mechanism, facilitates scalability to hundreds or thousands of devices. This work offers a practical and scalable solution for managing firmware in large-scale IoT deployments, contributing to enhanced device security, improved reliability, and reduced operational expenditures.