slop

plans/rover learning service.md

@@ -799,3 +799,25 @@ Format 2 snapshots, Latest/Previous, recordings and current training state remai
 This supersedes earlier promises to preserve incompatible format 1 model files.
 Deletion occurs on the actual server when the updated service starts; no production
 files were accessed from this development machine.
+
+
+### Recording maintenance race and diagnostic error details
+
+Authorized by "fix it and fix that IPI" after a production report showed two
+maintenance failures but omitted their error details. Scoped to those two defects;
+evaluation/cache changes remain proposals, not part of this repair.
+
+- listRecordings now tolerates ENOENT for directories/files removed between listing
+  and stat (dock-buffer pruning or atomic metadata rename). Other filesystem
+  errors still propagate; no broad error suppression or retries were added.
+- Diagnostics reportVersion 2 includes actual redacted error messages, rejection
+  reasons, controller results, event detail, and worker stderr. Runtime catches
+  retain error name/code/syscall/path/stack, timestamp and operation. Recording
+  failures retain the same structured details through session finalization.
+- A shared redactor removes URLs, credentials, user keys, email addresses and home
+  usernames while retaining filesystem operation context and stack frames. Error
+  categories remain supplementary, not replacements for actual failures.
+- Node syntax checks passed for affected modules. No actual production recording
+  stream is available here; the race is fixed by inspection but cannot yet be
+  confirmed as the cause of the earlier production events. Previously discarded
+  error details cannot be reconstructed. No new tests or processes were created.

server/src/services/roverLearningService/diagnostics.js

@@ -1,4 +1,5 @@
 // Export an explicit allowlist, never the raw socket/session/configuration object.
+const { redact } = require('./errors');
 const os = require('node:os');
 const fs = require('node:fs');
 const path = require('node:path');
@@ -6,7 +7,7 @@ const { createHash } = require('node:crypto');
 const applicationVersion = require('../../../package.json').version;
 const hash = createHash('sha256');
 for (const file of ['workers/policy.py', 'workers/dataset.py', 'workers/train.py', 'workers/infer.py',
-  'models.js', 'driving.js', 'recording.js', 'training.js', 'socketGateway.js', 'diagnostics.js']) {
+  'errors.js', 'storage.js', 'runtime.js', 'models.js', 'driving.js', 'recording.js', 'training.js', 'socketGateway.js', 'diagnostics.js']) {
   hash.update(fs.readFileSync(path.join(__dirname, file)));
 }
 const implementationSha256 = hash.digest('hex');
@@ -28,7 +29,7 @@ function report(state, controller) {
   const metrics = training.diagnostics || {};
   const session = state.session;
   return {
-    reportVersion: 1, generatedAtUnixMs: state.updatedAt,
+    reportVersion: 2, generatedAtUnixMs: state.updatedAt,
     software: { applicationVersion, implementationSha256, policyVersion: 2, node: process.version,
       dependencies: metrics.dependencies || null },
     host: { logicalCpus: os.cpus().length, totalMemoryBytes: os.totalmem(), freeMemoryBytes: os.freemem(), loadAverage: os.loadavg() },
@@ -37,23 +38,23 @@ function report(state, controller) {
       freeBytes: state.recording.freeBytes, pendingBytes: state.recording.pendingBytes,
       droppedPending: state.recording.droppedPending,
       sessions: state.recording.sessions.map((item) => ({ startedAtUnixMs: item.startedAt,
-        status: item.video, droppedEvents: item.droppedEvents, errorCategory: errorCategory(item.error) })) },
+        status: item.video, droppedEvents: item.droppedEvents, error: redact(item.error), failureDetails: item.failureDetails || null, stderr: redact(item.stderr), errorCategory: errorCategory(item.error) })) },
     training: { status: training.status, steps: training.steps, examples: training.examples,
       loss: training.loss, losses: training.losses || null, publication: training.publication || null,
       evaluation: training.evaluation || null, dataset: metrics.dataset || training.dataset || null,
       resources: { decodeSeconds: metrics.decodeSeconds ?? null, trainingSeconds: metrics.trainingSeconds ?? null,
         evaluationSeconds: metrics.evaluationSeconds ?? null, checkpointSeconds: metrics.checkpointSeconds ?? null, cpuSeconds: metrics.cpuSeconds ?? null,
         peakRssMiB: metrics.peakRssMiB ?? null },
-      history: training.history || [], rejectionCategories: (training.rejectionReasons || []).map(errorCategory),
+      history: training.history || [], rejectionReasons: (training.rejectionReasons || []).map(redact), rejectionCategories: (training.rejectionReasons || []).map(errorCategory),
-      errorCategory: errorCategory(training.error), nextAttemptAtUnixMs: training.nextAttemptAt },
+      error: redact(training.error), errorCategory: errorCategory(training.error), nextAttemptAtUnixMs: training.nextAttemptAt },
     model: session ? { id: session.modelId, checkpointId: session.checkpointId, threshold: session.threshold, appliedThreshold: session.appliedThreshold } : null,
     controller: controller ? { modelId: controller.modelId, sensorPresent: controller.sensorPresent || null,
-      stopCategory: errorCategory(controller.stopReason), history: (controller.history || []).map((item) => ({
+      stopReason: redact(controller.stopReason), stopCategory: errorCategory(controller.stopReason), history: (controller.history || []).map((item) => ({
         ...item, submissions: item.submissions.map((submission) => ({ type: submission.type,
-          wheels: submission.wheels, result: submission.result === 'issued' ? 'issued' : errorCategory(submission.result) })) })) } : null,
+          wheels: submission.wheels, result: redact(submission.result) })) })) } : null,
     sensorFields: metrics.policy?.sensorFields || null,
     timing: { alignment: 'server_receipt', browserVideoLatencyMs: null, wheelCommandExpiryMs: null },
-    events: state.activity.map(({ at, message }) => ({ atUnixMs: at, message })),
+    events: state.activity.map(({ at, message, detail, error, stderr }) => ({ atUnixMs: at, message: redact(message), detail: redact(detail), error: error || null, stderr: redact(stderr) })),
     unavailable: ['browser_video_latency', 'actual_physical_command_execution', 'live_training_cpu_utilization'],
   };
 }

server/src/services/roverLearningService/errors.js

@@ -0,0 +1,18 @@
+// Keep actionable failures while removing credentials and user identifiers.
+function redact(value) {
+  if (value == null) return null;
+  return String(value).slice(0, 12000)
+    .replace(/\b(?:https?|rtsp|rtsps):\/\/[^\s'"<>]+/gi, '[redacted URL]')
+    .replace(/\b(Bearer\s+)\S+/gi, '$1[redacted]')
+    .replace(/((?:password|token|secret|authorization|cookie|api[_-]?key)\s*[=:]\s*)[^\s,;]+/gi, '$1[redacted]')
+    .replace(/\bcu_[a-z0-9]+/gi, '[redacted user]')
+    .replace(/\b[A-Z0-9._%+-]+@[A-Z0-9.-]+\.[A-Z]{2,}\b/gi, '[redacted email]')
+    .replace(/\/(?:home|Users)\/[^/\s]+/g, '/[user]');
+}
+function errorDetails(error, operation) {
+  return { atUnixMs: Date.now(), operation: redact(operation),
+    name: redact(error?.name), message: redact(error?.message ?? error),
+    code: redact(error?.code), syscall: redact(error?.syscall),
+    path: redact(error?.path), stack: redact(error?.stack) };
+}
+module.exports = { redact, errorDetails };

server/src/services/roverLearningService/recording.js

@@ -1,5 +1,6 @@
 // One bounded recording session. Video packets retain receiver wall-clock PTS;
 // telemetry uses the same server clock, not an assumed browser playback clock.
+const { errorDetails, redact } = require('./errors');
 const fs = require('node:fs');
 const fsp = require('node:fs/promises');
 const path = require('node:path');
@@ -34,6 +35,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
   let dockedAt = null;
   let pruning = Promise.resolve();
   let failure = null;
+  let failureDetails = null;
   let stopping = false;
   let stopPromise;
   let child;
@@ -43,7 +45,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
   let resolveVideo;
   const videoClosed = new Promise((resolve) => { resolveVideo = resolve; });
   output.on('error', (error) => {
-    failure = error.message;
+    failure = error.message; failureDetails = errorDetails(error, 'recording session');
     // Stop file growth immediately when telemetry is no longer writable.
     child?.kill('SIGTERM');
   });
@@ -76,7 +78,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
       output.write(line);
     } catch (error) {
       metadata.droppedEvents += 1;
-      failure = error.message;
+      failure = error.message; failureDetails = errorDetails(error, 'recording session');
       child?.kill('SIGTERM');
     }
     return true;
@@ -97,7 +99,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
     '-reset_timestamps', '0', path.join(directory, 'video-%09d.mkv'),
   ], { stdio: ['ignore', 'ignore', 'pipe'] });
   child.stderr.on('data', (chunk) => { stderr = (stderr + chunk.toString()).slice(-4096); });
-  child.on('error', (error) => { failure = error.message; });
+  child.on('error', (error) => { failure = error.message; failureDetails = errorDetails(error, 'recording session'); });
   child.once('close', (code, signal) => {
     childClosed = true;
     videoResult = { code, signal, stderr };
@@ -131,7 +133,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
         if (!metadata.bufferOnly || stopping) return;
         if (stat.mtimeMs < Date.now() - 5000) await fsp.unlink(filename);
       }
-    }).catch((error) => { failure = error.message; child.kill('SIGTERM'); });
+    }).catch((error) => { failure = error.message; failureDetails = errorDetails(error, 'recording session'); child.kill('SIGTERM'); });
   }
 
   async function stop(reason) {
@@ -158,9 +160,10 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
       metadata.endedAt = Date.now();
       metadata.reason = reason;
       metadata.error = failure;
+      metadata.failureDetails = failureDetails;
       metadata.video.result = videoResult;
       await saveMetadata(directory, metadata);
-      if (failure) logger.warn('Recording session incomplete', { roverId, id, error: failure, stderr });
+      if (failure) logger.warn('Recording session incomplete', { roverId, id, error: failure, failure: failureDetails, stderr });
     })();
     return stopPromise;
   }
@@ -173,7 +176,7 @@ async function createRecording({ root, roverId, snapshot, logger, docked = false
     get failed() { return Boolean(failure); },
     get stopping() { return stopping; },
     getStatus: () => ({ id, roverId, startedAt: metadata.startedAt, droppedEvents: metadata.droppedEvents,
-      video: childClosed ? 'stopped' : metadata.bufferOnly ? 'Dock lead-in buffer' : 'Recording human driving', error: failure, stopping }),
+      video: childClosed ? 'stopped' : metadata.bufferOnly ? 'Dock lead-in buffer' : 'Recording human driving', error: redact(failure), failureDetails, stderr: redact(stderr), stopping }),
     // Process exit is synchronous; normal disable uses stop() and awaits close.
     kill: () => { if (!childClosed) child.kill('SIGKILL'); },
   };

server/src/services/roverLearningService/runtime.js

@@ -1,4 +1,5 @@
 // Enabled-only recording, training, controller, and card lifecycle.
+const { redact, errorDetails } = require('./errors');
 const fs = require('node:fs/promises');
 const path = require('node:path');
 const { resolveDataPath } = require('../../helpers/dataPaths');
@@ -22,7 +23,9 @@ function createRuntime({ config, logger }) {
   const recentActivity = [];
   function activity(message, details = {}) {
     recentActivity.push({ at: Date.now(), message, roverId: details.roverId || null,
-      detail: details.reason || details.error || details.model || null });
+      detail: redact(details.reason || details.error || details.model),
+      error: details.failure || (details.error ? errorDetails(details.error, message) : null),
+      stderr: redact(details.stderr) });
     if (recentActivity.length > 40) recentActivity.shift();
   }
   const baseLogger = logger;
@@ -77,7 +80,7 @@ function createRuntime({ config, logger }) {
     // The serialized maintenance pass still owns closing/removing the session.
     for (const [id, session] of sessions) {
       if (!next.has(id)) session.stop('no-human-controller').catch((error) => {
-        logger.warn('Unable to finalize unattended recording', { roverId: id, error: error.message });
+        logger.warn('Unable to finalize unattended recording', { roverId: id, error: error.message, failure: errorDetails(error, 'rover learning runtime') });
       });
     }
     schedule();
@@ -185,7 +188,7 @@ function createRuntime({ config, logger }) {
         await trainer.tick(new Set([...sessions.values()].map((session) => session.id)));
       } catch (error) {
         // Training availability must not tear down otherwise healthy capture.
-        logger.error('Unable to schedule training', { error: error.message });
+        logger.error('Unable to schedule training', { error: error.message, failure: errorDetails(error, 'rover learning runtime') });
       }
     }
   }
@@ -198,7 +201,7 @@ function createRuntime({ config, logger }) {
     // The next tick is scheduled after completion: disk slowness cannot build
     // an unbounded backlog of retention tasks or overlapping recorder starts.
     maintenance = maintain().catch(async (error) => {
-      logger.error('Recording maintenance failed; closing recorders', { error: error.message });
+      logger.error('Recording maintenance failed; closing recorders', { error: error.message, failure: errorDetails(error, 'recording maintenance') });
       await Promise.allSettled([...sessions.keys()].map((id) => closeSession(id, 'storage-error')));
     }).finally(() => {
       busy = false;
@@ -216,7 +219,7 @@ function createRuntime({ config, logger }) {
     // Other server services can exit the process before asynchronous cleanup
     // finishes. Signal children immediately, and keep an exit fallback too.
     for (const session of sessions.values()) session.stop('server-shutdown').catch(() => undefined);
-    stop().catch((error) => logger.warn('Recording shutdown failed', { error: error.message }));
+    stop().catch((error) => logger.warn('Recording shutdown failed', { error: error.message, failure: errorDetails(error, 'rover learning runtime') }));
   }
 
   async function start() {

server/src/services/roverLearningService/storage.js

@@ -10,9 +10,17 @@ async function listRecordings(root) {
     if (!entry.isDirectory() || !/^\d+-[0-9a-f-]{36}$/.test(entry.name)) continue;
     const directory = path.join(root, entry.name);
     let bytes = 0;
-    for (const file of await fs.readdir(directory, { withFileTypes: true })) {
+    let files;
+    try { files = await fs.readdir(directory, { withFileTypes: true }); }
+    catch (error) { if (error.code === 'ENOENT') continue; throw error; }
+    for (const file of files) {
       if (!file.isFile()) continue;
-      bytes += (await fs.stat(path.join(directory, file.name))).size;
+      try { bytes += (await fs.stat(path.join(directory, file.name))).size; }
+      catch (error) {
+        // Dock-buffer pruning and atomic metadata replacement can remove a
+        // listed file before stat. Absence is normal; other I/O failures are not.
+        if (error.code !== 'ENOENT') throw error;
+      }
     }
     recordings.push({ id: entry.name, directory, bytes, startedAt: Number(entry.name.split('-')[0]) });
   }

server/src/services/roverLearningService/training.js

@@ -1,5 +1,6 @@
 // One owned finite worker at a time. Leases are acquired in the runtime's
 // serialized maintenance pass, before retention can next inspect recordings.
+const { errorDetails } = require('./errors');
 const fs = require('node:fs/promises');
 const path = require('node:path');
 const { spawn } = require('node:child_process');
@@ -40,7 +41,7 @@ function createTrainer({ root, config, actionThreshold, logger }) {
     } catch (error) {
       startupError = true;
       state = { ...state, status: 'error', error: error.message };
-      logger.error('Training initialization failed; recording remains available', { error: error.message });
+      logger.error('Training initialization failed; recording remains available', { error: error.message, failure: errorDetails(error, 'training initialization') });
     }
   }
 
@@ -148,7 +149,7 @@ function createTrainer({ root, config, actionThreshold, logger }) {
           }
         } catch (error) {
           state = { ...state, status: 'error', error: error.message };
-          logger.error('Training result persistence failed', { error: error.message });
+          logger.error('Training result persistence failed', { error: error.message, failure: errorDetails(error, 'training result persistence') });
         } finally {
           history.push({ at: Date.now(), status: state.status, steps: state.steps, loss: state.loss,
             losses: state.losses || null, evaluation: state.evaluation || null,