runAb() in scripts/_cipc_service.js resolved only on proc.on('close'),
but agent-browser is a daemon-per-session CLI. When it has to START the
session browser daemon (first call after a reboot, after the daemon died,
or after the app restarts), the new daemon inherits the spawned CLI
stdout pipe. The pipe then never reaches EOF, so Node 'close' event
never fires - even though the CLI exited cleanly with code 0. The 30s
timeout in runAb called proc.kill(SIGTERM), but the process had already
exited, so the kill was a no-op and the promise never settled. The
wrapper serialised mutex then held inFlight forever, every later request
queued behind it, and CIPC search silently 500-ed for days with no log
line to show why - which is what made this look like a flaky / restart-
only issue.
Fixes:
- runAb now settles on 'exit' (with a 250ms flush grace for stdio to
drain), escalates the timeout kill to SIGKILL, and guarantees an
unconditional forced settle if neither fires. The promise can no
longer remain pending.
- app/api/cipc/search/route.ts: ensureWrapperService() now probes port
6002 on every search and respawns the wrapper (rate-limited to once
per 30s) if it is down. Hot reloads still no-op once a wrapper is up,
but a dead wrapper now self-heals instead of 500-ing forever.
Verified end to end: killed the browser daemon and the wrapper, started
a fresh wrapper, its first isWarm() spawned a new daemon (the previous
deadlock path) and returned in under 1s. A real enterprise search of
K2018435959 came back in 31.7s on the cold path and 50.9s on the warm
path with full company + director data.
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