Show useful local speech crash details

[boudra]

Linked issue

Type of change

• Bug fix
• New feature (with prior issue + design alignment)
• Refactor / code improvement
• Docs

What does this PR do

Local speech worker failures now leave useful breadcrumbs for both users and maintainers. When the native speech worker exits, the daemon logs the worker pid, exit code or signal, active/pending request context, and a bounded stderr tail; the app-facing error now includes the exit status, the request being handled, and the last stderr line when available.

This also prevents an unobserved session error from throwing out of the worker boundary while the pending connect promise is already carrying the failure.

How did you verify it

• npx vitest run src/server/speech/providers/local/worker-client.test.ts --bail=1
• npm run typecheck
• npm run lint
• npm run format
• Pre-commit hook reran staged-file lint, format check, and typecheck successfully.

Checklist

• One focused change. Unrelated cleanups split out.
• npm run typecheck passes
• npm run lint passes
• npm run format ran (Biome)
• UI changes include screenshots or video for every affected platform
• Tests added or updated where it made sense

Risk surface

This changes daemon-side local speech process handling. The main behavior risk is around stderr piping and error propagation for the worker child process; the new regression test covers the crash path and existing tests cover normal TTS, STT, VAD, idle shutdown, and IPC backpressure behavior.

[greptile-apps]

Greptile Summary

When the native speech worker exits unexpectedly, the daemon now logs the worker PID, exit code/signal, pending request context, and a bounded stderr tail; the user-facing error is enriched with the same context. A WeakSet tracks intentional worker closes so crash logging is suppressed for graceful shutdowns.

• Switches the exit listener from "exit" to "close", guaranteeing all stderr "data" events have fired before the crash handler reads stderrTail.
• Adds stderr piping (stdio: "pipe") and a streaming per-line logger alongside a bounded raw tail accumulator, with emitErrorIfObserved preventing unobserved EventEmitter errors from throwing unhandled.
• Two new test cases verify the crash log structure (using a capturing pino transport) and confirm intentional shutdowns do not produce an error-level log entry.

Confidence Score: 5/5

Safe to merge. The crash-path logic is well-structured and the new tests verify both the error content and the intentional-shutdown discrimination.

The switch from exit to close is correct and tested. The intentional-close WeakSet, bounded stderr accumulator, and enriched error message all work as intended. The two identified gaps are observability nits that do not affect correctness of crash detection or error propagation.

No files require special attention beyond the two suggestions already left.

Important Files Changed

Filename	Overview
packages/server/src/server/speech/providers/local/worker-client.ts	Core change: switches from exit to close event, adds stderr piping, structured logging on crash/shutdown, and a WeakSet to distinguish intentional closes. The last partial stderr line is never flushed to the per-line logger.warn before the exit record is written.
packages/server/src/server/speech/providers/local/worker-client.test.ts	New crash-path and intentional-shutdown tests using a capturing logger; dead emit(exit) left over from the old exit-event path is a harmless but misleading no-op.
packages/server/src/server/speech/providers/local/runtime.ts	Trivial one-line addition passing the module-level logger into LocalSpeechWorkerClient, now required by the new constructor option.

Flowchart

%%{init: {'theme': 'neutral'}}%%
flowchart TD
    A["worker 'close' event fires"] --> B{"intentionalWorkerCloses.has(worker)?"}
    B -- yes --> C["logger.info: closed after shutdown"]
    C --> D["null out this.worker if current"]
    D --> Z[return]
    B -- no --> E{wasCurrentWorker?}
    E -- no --> F["logger.warn: Stale worker closed"]
    F --> Z
    E -- yes --> G["buildWorkerExitMessage\ncode + signal + pendingRequests + stderrTail"]
    G --> H["logger.error: Local speech worker exited"]
    H --> I["null out this.worker / workerPid"]
    I --> J[clearIdleTimer]
    J --> K[rejectAllPending]
    K --> L["for each active session emitter"]
    L --> M{"listenerCount('error') > 0?"}
    M -- yes --> N["emitter.emit('error')"]
    M -- no --> O["logger.warn: session error had no listener"]
    N --> P["clear sessions, reset inFlightRequests"]
    O --> P

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_{Reviews (4): Last reviewed commit: "Avoid false speech worker crash logs on ..." | Re-trigger Greptile}