@afcec , Thanks for the detailed question. Apologies you’re experiencing this issue.
-As I understand the issue only affects iOS device, 1/10 times it works and also you mentioned about (1) configurating the APNS for both, production and sandbox application modes – just to clarify -
(if you haven’t done this already)- You must upload the certificate you use in a sandbox environment to a separate hub than the certificate/hub you'll use in production. If you have uploaded different types of certificates to the same hub. It may cause notification failures.
--If you inadvertently upload different types of certificates to the same hub, you should delete the hub and start fresh with a new hub. If for some reason you can't delete the hub, you must at least delete all the existing registrations from the hub. || Reference -APN configuration
--If you're leveraging a lower tier, please try upgrading to an higher tier and perform a quick test.
--Also, review Diagnose and solve problems blade to fetch some more details about the error -
Navigate to your Notification Hub on Azure Portal and select ‘Diagnose and solve problems’