fm-rds-tx/internal/app/engine.go

package app

import (
	"context"
	"errors"
	"fmt"
	"log"
	"sync"
	"sync/atomic"
	"time"

	"github.com/jan/fm-rds-tx/internal/audio"
	cfgpkg "github.com/jan/fm-rds-tx/internal/config"
	"github.com/jan/fm-rds-tx/internal/dsp"
	offpkg "github.com/jan/fm-rds-tx/internal/offline"
	"github.com/jan/fm-rds-tx/internal/output"
	"github.com/jan/fm-rds-tx/internal/platform"
)

type EngineState int

const (
	EngineIdle EngineState = iota
	EngineRunning
	EngineStopping
)

func (s EngineState) String() string {
	switch s {
	case EngineIdle:
		return "idle"
	case EngineRunning:
		return "running"
	case EngineStopping:
		return "stopping"
	default:
		return "unknown"
	}
}

type RuntimeState string

const (
	RuntimeStateIdle         RuntimeState = "idle"
	RuntimeStateArming       RuntimeState = "arming"
	RuntimeStatePrebuffering RuntimeState = "prebuffering"
	RuntimeStateRunning      RuntimeState = "running"
	RuntimeStateDegraded     RuntimeState = "degraded"
	RuntimeStateMuted        RuntimeState = "muted"
	RuntimeStateFaulted      RuntimeState = "faulted"
	RuntimeStateStopping     RuntimeState = "stopping"
)

func updateMaxDuration(dst *atomic.Uint64, d time.Duration) {
	v := uint64(d)
	for {
		cur := dst.Load()
		if v <= cur {
			return
		}
		if dst.CompareAndSwap(cur, v) {
			return
		}
	}
}

func durationMs(ns uint64) float64 {
	return float64(ns) / float64(time.Millisecond)
}

type EngineStats struct {
	State            string            `json:"state"`
	ChunksProduced   uint64            `json:"chunksProduced"`
	TotalSamples     uint64            `json:"totalSamples"`
	Underruns        uint64            `json:"underruns"`
	LateBuffers      uint64            `json:"lateBuffers,omitempty"`
	LastError        string            `json:"lastError,omitempty"`
	UptimeSeconds    float64           `json:"uptimeSeconds"`
	MaxCycleMs       float64           `json:"maxCycleMs,omitempty"`
	MaxGenerateMs    float64           `json:"maxGenerateMs,omitempty"`
	MaxUpsampleMs    float64           `json:"maxUpsampleMs,omitempty"`
	MaxWriteMs       float64           `json:"maxWriteMs,omitempty"`
	Queue            output.QueueStats `json:"queue"`
	RuntimeIndicator RuntimeIndicator  `json:"runtimeIndicator"`
	RuntimeAlert     string            `json:"runtimeAlert,omitempty"`
	LastFault        *FaultEvent       `json:"lastFault,omitempty"`
}

type RuntimeIndicator string

const (
	RuntimeIndicatorNormal        RuntimeIndicator = "normal"
	RuntimeIndicatorDegraded      RuntimeIndicator = "degraded"
	RuntimeIndicatorQueueCritical RuntimeIndicator = "queueCritical"
)

const (
	lateBufferIndicatorWindow    = 5 * time.Second
	queueCriticalStreakThreshold = 3
	queueMutedStreakThreshold    = queueCriticalStreakThreshold * 2
	queueMutedRecoveryThreshold  = queueCriticalStreakThreshold
	faultRepeatWindow            = 1 * time.Second
	faultHistoryCapacity         = 8
)

// Engine is the continuous TX loop. It generates composite IQ in chunks,
// resamples to device rate, and pushes to hardware in a tight loop.
// The hardware buffer_push call is blocking — it returns when the hardware
// has consumed the previous buffer and is ready for the next one.
// This naturally paces the loop to real-time without a ticker.
type Engine struct {
	cfg           cfgpkg.Config
	driver        platform.SoapyDriver
	generator     *offpkg.Generator
	upsampler     *dsp.FMUpsampler // nil = same-rate, non-nil = split-rate
	chunkDuration time.Duration
	deviceRate    float64
	frameQueue    *output.FrameQueue

	mu           sync.Mutex
	state        EngineState
	cancel       context.CancelFunc
	startedAt    time.Time
	wg           sync.WaitGroup
	runtimeState atomic.Value

	chunksProduced      atomic.Uint64
	totalSamples        atomic.Uint64
	underruns           atomic.Uint64
	lateBuffers         atomic.Uint64
	lateBufferAlertAt   atomic.Uint64
	criticalStreak      atomic.Uint64
	mutedRecoveryStreak atomic.Uint64
	maxCycleNs          atomic.Uint64
	maxGenerateNs       atomic.Uint64
	maxUpsampleNs       atomic.Uint64
	maxWriteNs          atomic.Uint64
	lastError           atomic.Value // string
	lastFault           atomic.Value // *FaultEvent
	faultHistoryMu      sync.Mutex
	faultHistory        []FaultEvent

	// Live config: pending frequency change, applied between chunks
	pendingFreq atomic.Pointer[float64]

	// Live audio stream (optional)
	streamSrc *audio.StreamSource
}

// SetStreamSource configures a live audio stream as the audio source.
// Must be called before Start(). The StreamResampler is created internally
// to convert from the stream's sample rate to the DSP composite rate.
func (e *Engine) SetStreamSource(src *audio.StreamSource) {
	e.streamSrc = src
	compositeRate := float64(e.cfg.FM.CompositeRateHz)
	if compositeRate <= 0 {
		compositeRate = 228000
	}
	resampler := audio.NewStreamResampler(src, compositeRate)
	e.generator.SetExternalSource(resampler)
	log.Printf("engine: live audio stream — %d Hz → %.0f Hz (buffer %d frames)",
		src.SampleRate, compositeRate, src.Stats().Capacity)
}

// StreamSource returns the live audio stream source, or nil.
// Used by the control server for stats and HTTP audio ingest.
func (e *Engine) StreamSource() *audio.StreamSource {
	return e.streamSrc
}

func NewEngine(cfg cfgpkg.Config, driver platform.SoapyDriver) *Engine {
	deviceRate := cfg.EffectiveDeviceRate()
	compositeRate := float64(cfg.FM.CompositeRateHz)
	if compositeRate <= 0 {
		compositeRate = 228000
	}

	var upsampler *dsp.FMUpsampler

	if deviceRate > compositeRate*1.001 {
		// Split-rate: DSP chain runs at compositeRate (typ. 228 kHz),
		// FMUpsampler handles FM modulation + interpolation to deviceRate.
		// This halves CPU load compared to running all DSP at deviceRate.
		cfg.FM.FMModulationEnabled = false
		maxDev := cfg.FM.MaxDeviationHz
		if maxDev <= 0 {
			maxDev = 75000
		}
		// mpxGain scales the FM deviation to compensate for hardware
		// DAC/SDR scaling factors. DSP chain stays at logical 0-1.0 levels.
		if cfg.FM.MpxGain > 0 && cfg.FM.MpxGain != 1.0 {
			maxDev *= cfg.FM.MpxGain
		}
		upsampler = dsp.NewFMUpsampler(compositeRate, deviceRate, maxDev)
		log.Printf("engine: split-rate mode — DSP@%.0fHz → upsample@%.0fHz (ratio %.2f)",
			compositeRate, deviceRate, deviceRate/compositeRate)
	} else {
		// Same-rate: entire DSP chain runs at deviceRate.
		// Used when deviceRate ≈ compositeRate (e.g. LimeSDR at 228 kHz).
		if deviceRate > 0 {
			cfg.FM.CompositeRateHz = int(deviceRate)
		}
		cfg.FM.FMModulationEnabled = true
		log.Printf("engine: same-rate mode — DSP@%dHz", cfg.FM.CompositeRateHz)
	}

	engine := &Engine{
		cfg:           cfg,
		driver:        driver,
		generator:     offpkg.NewGenerator(cfg),
		upsampler:     upsampler,
		chunkDuration: 50 * time.Millisecond,
		deviceRate:    deviceRate,
		state:         EngineIdle,
		frameQueue:    output.NewFrameQueue(cfg.Runtime.FrameQueueCapacity),
		faultHistory:  make([]FaultEvent, 0, faultHistoryCapacity),
	}
	engine.setRuntimeState(RuntimeStateIdle)
	return engine
}

func (e *Engine) SetChunkDuration(d time.Duration) {
	e.chunkDuration = d
}

// LiveConfigUpdate carries hot-reloadable parameters from the control API.
// nil pointers mean "no change". Validated before applying.
type LiveConfigUpdate struct {
	FrequencyMHz   *float64
	OutputDrive    *float64
	StereoEnabled  *bool
	PilotLevel     *float64
	RDSInjection   *float64
	RDSEnabled     *bool
	LimiterEnabled *bool
	LimiterCeiling *float64
	PS             *string
	RadioText      *string
}

// UpdateConfig applies live parameter changes without restarting the engine.
// DSP params take effect at the next chunk boundary (~50ms max).
// Frequency changes are applied between chunks via driver.Tune().
// RDS text updates are applied at the next RDS group boundary (~88ms).
func (e *Engine) UpdateConfig(u LiveConfigUpdate) error {
	// --- Validate ---
	if u.FrequencyMHz != nil {
		if *u.FrequencyMHz < 65 || *u.FrequencyMHz > 110 {
			return fmt.Errorf("frequencyMHz out of range (65-110)")
		}
	}
	if u.OutputDrive != nil {
		if *u.OutputDrive < 0 || *u.OutputDrive > 10 {
			return fmt.Errorf("outputDrive out of range (0-10)")
		}
	}
	if u.PilotLevel != nil {
		if *u.PilotLevel < 0 || *u.PilotLevel > 0.2 {
			return fmt.Errorf("pilotLevel out of range (0-0.2)")
		}
	}
	if u.RDSInjection != nil {
		if *u.RDSInjection < 0 || *u.RDSInjection > 0.15 {
			return fmt.Errorf("rdsInjection out of range (0-0.15)")
		}
	}
	if u.LimiterCeiling != nil {
		if *u.LimiterCeiling < 0 || *u.LimiterCeiling > 2 {
			return fmt.Errorf("limiterCeiling out of range (0-2)")
		}
	}

	// --- Frequency: store for run loop to apply via driver.Tune() ---
	if u.FrequencyMHz != nil {
		freqHz := *u.FrequencyMHz * 1e6
		e.pendingFreq.Store(&freqHz)
	}

	// --- RDS text: forward to encoder atomics ---
	if u.PS != nil || u.RadioText != nil {
		if enc := e.generator.RDSEncoder(); enc != nil {
			ps, rt := "", ""
			if u.PS != nil {
				ps = *u.PS
			}
			if u.RadioText != nil {
				rt = *u.RadioText
			}
			enc.UpdateText(ps, rt)
		}
	}

	// --- DSP params: build new LiveParams from current + patch ---
	// Read current, apply deltas, store new
	current := e.generator.CurrentLiveParams()
	next := current // copy

	if u.OutputDrive != nil {
		next.OutputDrive = *u.OutputDrive
	}
	if u.StereoEnabled != nil {
		next.StereoEnabled = *u.StereoEnabled
	}
	if u.PilotLevel != nil {
		next.PilotLevel = *u.PilotLevel
	}
	if u.RDSInjection != nil {
		next.RDSInjection = *u.RDSInjection
	}
	if u.RDSEnabled != nil {
		next.RDSEnabled = *u.RDSEnabled
	}
	if u.LimiterEnabled != nil {
		next.LimiterEnabled = *u.LimiterEnabled
	}
	if u.LimiterCeiling != nil {
		next.LimiterCeiling = *u.LimiterCeiling
	}

	e.generator.UpdateLive(next)
	return nil
}

func (e *Engine) Start(ctx context.Context) error {
	e.mu.Lock()
	if e.state != EngineIdle {
		e.mu.Unlock()
		return fmt.Errorf("engine already in state %s", e.state)
	}

	if err := e.driver.Start(ctx); err != nil {
		e.mu.Unlock()
		return fmt.Errorf("driver start: %w", err)
	}

	runCtx, cancel := context.WithCancel(ctx)
	e.cancel = cancel
	e.state = EngineRunning
	e.setRuntimeState(RuntimeStateArming)
	e.startedAt = time.Now()
	e.wg.Add(1)
	e.mu.Unlock()

	go e.run(runCtx)
	return nil
}

func (e *Engine) Stop(ctx context.Context) error {
	e.mu.Lock()
	if e.state != EngineRunning {
		e.mu.Unlock()
		return nil
	}
	e.state = EngineStopping
	e.setRuntimeState(RuntimeStateStopping)
	e.cancel()
	e.mu.Unlock()

	// Wait for run() goroutine to exit — deterministic, no guessing
	e.wg.Wait()

	if err := e.driver.Flush(ctx); err != nil {
		return err
	}
	if err := e.driver.Stop(ctx); err != nil {
		return err
	}

	e.mu.Lock()
	e.state = EngineIdle
	e.setRuntimeState(RuntimeStateIdle)
	e.mu.Unlock()
	return nil
}

func (e *Engine) Stats() EngineStats {
	e.mu.Lock()
	state := e.state
	startedAt := e.startedAt
	e.mu.Unlock()

	var uptime float64
	if state == EngineRunning {
		uptime = time.Since(startedAt).Seconds()
	}
	errVal, _ := e.lastError.Load().(string)

	queue := e.frameQueue.Stats()
	lateBuffers := e.lateBuffers.Load()
	hasRecentLateBuffers := e.hasRecentLateBuffers()
	ri := runtimeIndicator(queue.Health, hasRecentLateBuffers)
	lastFault := e.lastFaultEvent()
	return EngineStats{
		State:            string(e.currentRuntimeState()),
		ChunksProduced:   e.chunksProduced.Load(),
		TotalSamples:     e.totalSamples.Load(),
		Underruns:        e.underruns.Load(),
		LateBuffers:      lateBuffers,
		LastError:        errVal,
		UptimeSeconds:    uptime,
		MaxCycleMs:       durationMs(e.maxCycleNs.Load()),
		MaxGenerateMs:    durationMs(e.maxGenerateNs.Load()),
		MaxUpsampleMs:    durationMs(e.maxUpsampleNs.Load()),
		MaxWriteMs:       durationMs(e.maxWriteNs.Load()),
		Queue:            queue,
		RuntimeIndicator: ri,
		RuntimeAlert:     runtimeAlert(queue.Health, hasRecentLateBuffers),
		LastFault:        lastFault,
	}
}

func runtimeIndicator(queueHealth output.QueueHealth, recentLateBuffers bool) RuntimeIndicator {
	switch {
	case queueHealth == output.QueueHealthCritical:
		return RuntimeIndicatorQueueCritical
	case queueHealth == output.QueueHealthLow || recentLateBuffers:
		return RuntimeIndicatorDegraded
	default:
		return RuntimeIndicatorNormal
	}
}

func runtimeAlert(queueHealth output.QueueHealth, recentLateBuffers bool) string {
	switch {
	case queueHealth == output.QueueHealthCritical:
		return "queue health critical"
	case recentLateBuffers:
		return "late buffers"
	case queueHealth == output.QueueHealthLow:
		return "queue health low"
	default:
		return ""
	}
}

func (e *Engine) run(ctx context.Context) {
	e.setRuntimeState(RuntimeStatePrebuffering)
	e.wg.Add(1)
	go e.writerLoop(ctx)
	defer e.wg.Done()

	for {
		if ctx.Err() != nil {
			return
		}

		// Apply pending frequency change between chunks
		if pf := e.pendingFreq.Swap(nil); pf != nil {
			if err := e.driver.Tune(ctx, *pf); err != nil {
				e.lastError.Store(fmt.Sprintf("tune: %v", err))
			} else {
				log.Printf("engine: tuned to %.3f MHz", *pf/1e6)
			}
		}

		t0 := time.Now()
		frame := e.generator.GenerateFrame(e.chunkDuration)
		frame.GeneratedAt = t0
		t1 := time.Now()
		if e.upsampler != nil {
			frame = e.upsampler.Process(frame)
			frame.GeneratedAt = t0
		}
		t2 := time.Now()

		genDur := t1.Sub(t0)
		upDur := t2.Sub(t1)
		updateMaxDuration(&e.maxGenerateNs, genDur)
		updateMaxDuration(&e.maxUpsampleNs, upDur)

		enqueued := cloneFrame(frame)
		if enqueued == nil {
			e.lastError.Store("engine: frame clone failed")
			e.underruns.Add(1)
			continue
		}

		if err := e.frameQueue.Push(ctx, enqueued); err != nil {
			if ctx.Err() != nil {
				return
			}
			if errors.Is(err, output.ErrFrameQueueClosed) {
				return
			}
			e.lastError.Store(err.Error())
			e.underruns.Add(1)
			select {
			case <-time.After(e.chunkDuration):
			case <-ctx.Done():
				return
			}
			continue
		}
		queueStats := e.frameQueue.Stats()
		e.evaluateRuntimeState(queueStats, e.hasRecentLateBuffers())
	}
}

func (e *Engine) writerLoop(ctx context.Context) {
	defer e.wg.Done()
	for {
		frame, err := e.frameQueue.Pop(ctx)
		if err != nil {
			if ctx.Err() != nil {
				return
			}
			if errors.Is(err, output.ErrFrameQueueClosed) {
				return
			}
			e.lastError.Store(err.Error())
			e.underruns.Add(1)
			continue
		}

		writeStart := time.Now()
		n, err := e.driver.Write(ctx, frame)
		writeDur := time.Since(writeStart)

		cycleDur := writeDur
		if !frame.GeneratedAt.IsZero() {
			cycleDur = time.Since(frame.GeneratedAt)
		}

		updateMaxDuration(&e.maxWriteNs, writeDur)
		updateMaxDuration(&e.maxCycleNs, cycleDur)
		queueStats := e.frameQueue.Stats()
		e.evaluateRuntimeState(queueStats, e.hasRecentLateBuffers())

		if cycleDur > e.chunkDuration {
			late := e.lateBuffers.Add(1)
			e.lateBufferAlertAt.Store(uint64(time.Now().UnixNano()))
			if late <= 5 || late%20 == 0 {
				log.Printf("TX LATE: cycle=%s budget=%s write=%s over=%s",
					cycleDur, e.chunkDuration, writeDur, cycleDur-e.chunkDuration)
			}
		}

		if err != nil {
			if ctx.Err() != nil {
				return
			}
			e.lastError.Store(err.Error())
			e.underruns.Add(1)
			select {
			case <-time.After(e.chunkDuration):
			case <-ctx.Done():
				return
			}
			continue
		}

		e.chunksProduced.Add(1)
		e.totalSamples.Add(uint64(n))
	}
}

func cloneFrame(src *output.CompositeFrame) *output.CompositeFrame {
	if src == nil {
		return nil
	}
	samples := make([]output.IQSample, len(src.Samples))
	copy(samples, src.Samples)
	return &output.CompositeFrame{
		Samples:      samples,
		SampleRateHz: src.SampleRateHz,
		Timestamp:    src.Timestamp,
		GeneratedAt:  src.GeneratedAt,
		Sequence:     src.Sequence,
	}
}

func (e *Engine) setRuntimeState(state RuntimeState) {
	e.runtimeState.Store(state)
}

func (e *Engine) currentRuntimeState() RuntimeState {
	if v := e.runtimeState.Load(); v != nil {
		if rs, ok := v.(RuntimeState); ok {
			return rs
		}
	}
	return RuntimeStateIdle
}

func (e *Engine) hasRecentLateBuffers() bool {
	lateAlertAt := e.lateBufferAlertAt.Load()
	if lateAlertAt == 0 {
		return false
	}
	return time.Since(time.Unix(0, int64(lateAlertAt))) <= lateBufferIndicatorWindow
}

func (e *Engine) lastFaultEvent() *FaultEvent {
	return copyFaultEvent(e.loadLastFault())
}

// LastFault exposes the most recent captured fault, if any.
func (e *Engine) LastFault() *FaultEvent {
	return e.lastFaultEvent()
}

func (e *Engine) FaultHistory() []FaultEvent {
	e.faultHistoryMu.Lock()
	defer e.faultHistoryMu.Unlock()
	history := make([]FaultEvent, len(e.faultHistory))
	copy(history, e.faultHistory)
	return history
}

func (e *Engine) recordFault(reason FaultReason, severity FaultSeverity, message string) {
	if reason == "" {
		reason = FaultReasonUnknown
	}
	now := time.Now()
	if last := e.loadLastFault(); last != nil {
		if last.Reason == reason && last.Severity == severity && now.Sub(last.Time) < faultRepeatWindow {
			return
		}
	}
	ev := &FaultEvent{
		Time:     now,
		Reason:   reason,
		Severity: severity,
		Message:  message,
	}
	e.lastFault.Store(ev)
	e.appendFaultHistory(ev)
}

func (e *Engine) loadLastFault() *FaultEvent {
	if v := e.lastFault.Load(); v != nil {
		if ev, ok := v.(*FaultEvent); ok {
			return ev
		}
	}
	return nil
}

func copyFaultEvent(source *FaultEvent) *FaultEvent {
	if source == nil {
		return nil
	}
	copy := *source
	return &copy
}

func (e *Engine) appendFaultHistory(ev *FaultEvent) {
	e.faultHistoryMu.Lock()
	defer e.faultHistoryMu.Unlock()
	if len(e.faultHistory) >= faultHistoryCapacity {
		copy(e.faultHistory, e.faultHistory[1:])
		e.faultHistory[len(e.faultHistory)-1] = *ev
		return
	}
	e.faultHistory = append(e.faultHistory, *ev)
}

func (e *Engine) evaluateRuntimeState(queue output.QueueStats, hasLateBuffers bool) {
	state := e.currentRuntimeState()
	switch state {
	case RuntimeStateStopping, RuntimeStateFaulted:
		return
	case RuntimeStateMuted:
		if queue.Health == output.QueueHealthNormal && !hasLateBuffers {
			if count := e.mutedRecoveryStreak.Add(1); count >= queueMutedRecoveryThreshold {
				e.mutedRecoveryStreak.Store(0)
				e.recordFault(FaultReasonQueueCritical, FaultSeverityDegraded,
					fmt.Sprintf("queue healthy for %d checks after mute", count))
				e.setRuntimeState(RuntimeStateDegraded)
			}
		} else {
			e.mutedRecoveryStreak.Store(0)
		}
		return
	}
	if state == RuntimeStatePrebuffering {
		if queue.Depth >= 1 {
			e.setRuntimeState(RuntimeStateRunning)
		}
		return
	}
	critical := queue.Health == output.QueueHealthCritical
	if critical {
		count := e.criticalStreak.Add(1)
		if count >= queueMutedStreakThreshold {
			e.recordFault(FaultReasonQueueCritical, FaultSeverityMuted,
				fmt.Sprintf("queue health critical for %d consecutive checks (depth=%d)", count, queue.Depth))
			e.setRuntimeState(RuntimeStateMuted)
			return
		}
		if count >= queueCriticalStreakThreshold {
			e.recordFault(FaultReasonQueueCritical, FaultSeverityDegraded,
				fmt.Sprintf("queue health critical (depth=%d)", queue.Depth))
			e.setRuntimeState(RuntimeStateDegraded)
			return
		}
	} else {
		e.criticalStreak.Store(0)
	}
	if hasLateBuffers {
		e.recordFault(FaultReasonLateBuffers, FaultSeverityWarn,
			fmt.Sprintf("late buffers detected (health=%s)", queue.Health))
		e.setRuntimeState(RuntimeStateDegraded)
		return
	}
	e.setRuntimeState(RuntimeStateRunning)
}