Recover stale supervised daemons

Teach daemon stop to use lifecycle shutdown when the API is reachable even if the owner pid is stale, then wait for the API to disappear and clean the stale pidfile.

Launch desktop-managed daemons detached from desktop stdio, preserve stale reachable daemon ownership for version checks, and allow desktop stop/restart to use the CLI recovery path.

Add supervisor heartbeats so supervised workers shut down when their supervisor disappears instead of surviving as orphaned reachable daemons.

packages/desktop/src/daemon/daemon-manager.ts

@@ -43,7 +43,6 @@ const DAEMON_LOG_FILENAME = "daemon.log";
 const STARTUP_POLL_INTERVAL_MS = 200;
 const STARTUP_POLL_MAX_ATTEMPTS = 150;
 const DETACHED_STARTUP_GRACE_MS = 1200;
-const STARTUP_OUTPUT_CAPTURE_LIMIT_CHARS = 64 * 1024;
 
 type DesktopDaemonState = "starting" | "running" | "stopped" | "errored";
 
@@ -70,11 +69,6 @@ interface DesktopPairingOffer {
   qr: string | null;
 }
 
-interface StartupOutputCapture {
-  text: string;
-  truncated: boolean;
-}
-
 function parseReleaseChannel(
   args: Record<string, unknown> | undefined,
 ): AppReleaseChannel | undefined {
@@ -151,30 +145,6 @@ function tailFile(filePath: string, lines = 50): string {
   }
 }
 
-function createStartupOutputCapture(): StartupOutputCapture {
-  return { text: "", truncated: false };
-}
-
-function appendStartupOutput(capture: StartupOutputCapture, chunk: Buffer): StartupOutputCapture {
-  const nextText = capture.text + chunk.toString();
-  if (nextText.length <= STARTUP_OUTPUT_CAPTURE_LIMIT_CHARS) {
-    return { text: nextText, truncated: capture.truncated };
-  }
-
-  return {
-    text: nextText.slice(-STARTUP_OUTPUT_CAPTURE_LIMIT_CHARS),
-    truncated: true,
-  };
-}
-
-function formatStartupOutput(capture: StartupOutputCapture): string {
-  if (!capture.truncated) {
-    return capture.text;
-  }
-
-  return `[output truncated to the last ${STARTUP_OUTPUT_CAPTURE_LIMIT_CHARS} chars]\n${capture.text}`;
-}
-
 function logDesktopDaemonLifecycle(message: string, details?: Record<string, unknown>): void {
   log.info("[desktop daemon]", message, {
     pid: process.pid,
@@ -231,6 +201,7 @@ export async function resolveDesktopDaemonStatus(): Promise<DesktopDaemonStatus>
       typeof payload.connectedDaemon === "string" ? payload.connectedDaemon : "not_probed";
     const hasRunningLocalProcess = localDaemon === "running";
     const hasLocalProcess = hasRunningLocalProcess || localDaemon === "unresponsive";
+    const desktopManaged = payload.desktopManaged === true;
     const apiReachable = connectedDaemon === "reachable";
     let status: DesktopDaemonState = "stopped";
     if (apiReachable || hasRunningLocalProcess) {
@@ -248,7 +219,7 @@ export async function resolveDesktopDaemonStatus(): Promise<DesktopDaemonStatus>
       pid: hasLocalProcess && typeof payload.pid === "number" ? payload.pid : null,
       home,
       version: typeof payload.daemonVersion === "string" ? payload.daemonVersion : null,
-      desktopManaged: hasRunningLocalProcess && payload.desktopManaged === true,
+      desktopManaged,
       error: null,
     };
   } catch (error) {
@@ -287,19 +258,15 @@ function assertBuiltInDaemonManagementEnabled(settings: DesktopSettings): void {
   }
 }
 
-function buildStartupFailureError(
-  result: { code: number | null; signal: string | null; error?: Error },
-  stdout: StartupOutputCapture,
-  stderr: StartupOutputCapture,
-): Error {
+function buildStartupFailureError(result: {
+  code: number | null;
+  signal: string | null;
+  error?: Error;
+}): Error {
   const reason = result.error
     ? result.error.message
     : `exit code ${result.code ?? "unknown"}${result.signal ? ` (${result.signal})` : ""}`;
   const parts = [`Daemon failed to start: ${reason}`];
-  const formattedStderr = formatStartupOutput(stderr).trim();
-  const formattedStdout = formatStartupOutput(stdout).trim();
-  if (formattedStderr) parts.push(`stderr:\n${formattedStderr}`);
-  if (formattedStdout) parts.push(`stdout:\n${formattedStdout}`);
   const logs = tailFile(logFilePath(), 15);
   if (logs) parts.push(`Recent logs (${logFilePath()}):\n${logs}`);
   return new Error(parts.join("\n\n"));
@@ -377,16 +344,7 @@ async function startDaemon(): Promise<DesktopDaemonStatus> {
     envMode: "internal",
     env: invocation.env,
     envOverlay: { PASEO_DESKTOP_MANAGED: "1" },
-    stdio: ["ignore", "pipe", "pipe"],
-  });
-
-  let stdout = createStartupOutputCapture();
-  let stderr = createStartupOutputCapture();
-  child.stdout!.on("data", (data: Buffer) => {
-    stdout = appendStartupOutput(stdout, data);
-  });
-  child.stderr!.on("data", (data: Buffer) => {
-    stderr = appendStartupOutput(stderr, data);
+    stdio: ["ignore", "ignore", "ignore"],
   });
 
   logDesktopDaemonLifecycle("detached spawn returned", {
@@ -424,8 +382,6 @@ async function startDaemon(): Promise<DesktopDaemonStatus> {
   logDesktopDaemonLifecycle("detached startup grace period completed", {
     childPid: child.pid ?? null,
     exitedEarly: result.exitedEarly,
-    stdout: formatStartupOutput(stdout).slice(0, 2000),
-    stderr: formatStartupOutput(stderr).slice(0, 2000),
     ...(result.exitedEarly
       ? {
           exitCode: result.code,
@@ -436,7 +392,7 @@ async function startDaemon(): Promise<DesktopDaemonStatus> {
   });
 
   if (result.exitedEarly) {
-    throw buildStartupFailureError(result, stdout, stderr);
+    throw buildStartupFailureError(result);
   }
 
   return pollForRunningDaemon();
@@ -444,7 +400,7 @@ async function startDaemon(): Promise<DesktopDaemonStatus> {
 
 export async function stopDesktopDaemon(): Promise<DesktopDaemonStatus> {
   const status = await resolveDesktopDaemonStatus();
-  if (status.status !== "running" || !status.pid) return status;
+  if (status.status !== "running") return status;
 
   await stopDesktopDaemonViaCli();
   return await resolveDesktopDaemonStatus();