Add trace logging and tighten daemon log defaults (#933)

* Add trace logging and tighten daemon log defaults

* Clean up daemon trace logging shape

* Clean up daemon trace logging

* Route provider turn-id checks through shared helper

* Fix supervisor log config test paths on Windows

* Expect resolved supervisor log path on Windows

packages/server/scripts/supervisor-entrypoint.ts

@@ -10,12 +10,9 @@ import {
 import { resolvePaseoHome } from "../src/server/paseo-home.js";
 import { loadPersistedConfig } from "../src/server/persisted-config.js";
 import { runSupervisor } from "./supervisor.js";
+import { resolveSupervisorLogFile } from "./supervisor-log-config.js";
 import { applySherpaLoaderEnv } from "../src/server/speech/providers/local/sherpa/sherpa-runtime-env.js";
 
-const DEFAULT_DAEMON_LOG_FILENAME = "daemon.log";
-const DEFAULT_LOG_ROTATE_SIZE = "10m";
-const DEFAULT_LOG_ROTATE_MAX_FILES = 2;
-
 interface DaemonRunnerConfig {
   devMode: boolean;
   workerArgs: string[];
@@ -77,28 +74,6 @@ function resolvePackagedNodeEntrypointRunnerPath(currentScriptPath: string): str
   return existsSync(runnerPath) ? runnerPath : null;
 }
 
-function resolveSupervisorLogFile(
-  paseoHome: string,
-  persistedConfig: ReturnType<typeof loadPersistedConfig>,
-) {
-  const configuredFile = persistedConfig.log?.file;
-  const configuredPath = configuredFile?.path;
-  let logPath = path.join(paseoHome, DEFAULT_DAEMON_LOG_FILENAME);
-  if (configuredPath) {
-    logPath = path.isAbsolute(configuredPath)
-      ? configuredPath
-      : path.resolve(paseoHome, configuredPath);
-  }
-
-  return {
-    path: logPath,
-    rotate: {
-      maxSize: configuredFile?.rotate?.maxSize ?? DEFAULT_LOG_ROTATE_SIZE,
-      maxFiles: configuredFile?.rotate?.maxFiles ?? DEFAULT_LOG_ROTATE_MAX_FILES,
-    },
-  };
-}
-
 async function main(): Promise<void> {
   const config = parseConfig(process.argv.slice(2));
   const workerEntry = config.devMode ? resolveDevWorkerEntry() : resolveWorkerEntry();
@@ -113,7 +88,7 @@ async function main(): Promise<void> {
 
   const paseoHome = resolvePaseoHome(workerEnv);
   const persistedConfig = loadPersistedConfig(paseoHome);
-  const supervisorLogFile = resolveSupervisorLogFile(paseoHome, persistedConfig);
+  const supervisorLogFile = resolveSupervisorLogFile(paseoHome, persistedConfig, workerEnv);
 
   try {
     await acquirePidLock(paseoHome, null, {

packages/server/scripts/supervisor-log-config.ts

@@ -0,0 +1,42 @@
+import path from "node:path";
+
+import type { loadPersistedConfig } from "../src/server/persisted-config.js";
+
+const DEFAULT_DAEMON_LOG_FILENAME = "daemon.log";
+const DEFAULT_LOG_ROTATE_SIZE = "10m";
+const DEFAULT_LOG_ROTATE_MAX_FILES = 3;
+
+export function resolveSupervisorLogFile(
+  paseoHome: string,
+  persistedConfig: ReturnType<typeof loadPersistedConfig>,
+  env: NodeJS.ProcessEnv = process.env,
+) {
+  const configuredFile = persistedConfig.log?.file;
+  const configuredPath = configuredFile?.path;
+  const envRotateSize = env.PASEO_LOG_ROTATE_SIZE?.trim();
+  const envRotateMaxFiles = parseOptionalPositiveInteger(env.PASEO_LOG_ROTATE_COUNT);
+  let logPath = path.join(paseoHome, DEFAULT_DAEMON_LOG_FILENAME);
+  if (configuredPath) {
+    logPath = path.isAbsolute(configuredPath)
+      ? configuredPath
+      : path.resolve(paseoHome, configuredPath);
+  }
+
+  return {
+    path: logPath,
+    rotate: {
+      maxSize: configuredFile?.rotate?.maxSize ?? envRotateSize ?? DEFAULT_LOG_ROTATE_SIZE,
+      maxFiles:
+        configuredFile?.rotate?.maxFiles ?? envRotateMaxFiles ?? DEFAULT_LOG_ROTATE_MAX_FILES,
+    },
+  };
+}
+
+function parseOptionalPositiveInteger(value: string | undefined): number | undefined {
+  if (value === undefined) {
+    return undefined;
+  }
+
+  const parsed = Number.parseInt(value.trim(), 10);
+  return Number.isInteger(parsed) && parsed > 0 ? parsed : undefined;
+}

packages/server/scripts/supervisor.logging.test.ts

@@ -5,6 +5,7 @@ import { fileURLToPath, pathToFileURL } from "node:url";
 import { spawn } from "node:child_process";
 import { describe, expect, test } from "vitest";
 import { isPlatform } from "../src/test-utils/platform.js";
+import { resolveSupervisorLogFile } from "./supervisor-log-config.js";
 
 const repoRoot = path.resolve(fileURLToPath(new URL("../../..", import.meta.url)));
 const supervisorPath = fileURLToPath(new URL("./supervisor.ts", import.meta.url));
@@ -87,6 +88,57 @@ async function runSupervisorFixture(options: {
 }
 
 describe("supervisor durable logging", () => {
+  test("resolves rotation defaults", () => {
+    const paseoHome = path.join(path.sep, "tmp", "paseo-home");
+    const logFile = resolveSupervisorLogFile(paseoHome, {}, {});
+
+    expect(logFile).toEqual({
+      path: path.join(paseoHome, "daemon.log"),
+      rotate: { maxSize: "10m", maxFiles: 3 },
+    });
+  });
+
+  test("lets persisted rotation override env rotation defaults", () => {
+    const paseoHome = path.join(path.sep, "tmp", "paseo-home");
+    const logFile = resolveSupervisorLogFile(
+      paseoHome,
+      {
+        log: {
+          file: {
+            path: "logs/daemon.log",
+            rotate: { maxSize: "25m", maxFiles: 4 },
+          },
+        },
+      },
+      {
+        PASEO_LOG_ROTATE_SIZE: "200m",
+        PASEO_LOG_ROTATE_COUNT: "12",
+      },
+    );
+
+    expect(logFile).toEqual({
+      path: path.resolve(paseoHome, "logs", "daemon.log"),
+      rotate: { maxSize: "25m", maxFiles: 4 },
+    });
+  });
+
+  test("uses env rotation when persisted rotation is absent", () => {
+    const paseoHome = path.join(path.sep, "tmp", "paseo-home");
+    const logFile = resolveSupervisorLogFile(
+      paseoHome,
+      {},
+      {
+        PASEO_LOG_ROTATE_SIZE: "50m",
+        PASEO_LOG_ROTATE_COUNT: "8",
+      },
+    );
+
+    expect(logFile).toEqual({
+      path: path.join(paseoHome, "daemon.log"),
+      rotate: { maxSize: "50m", maxFiles: 8 },
+    });
+  });
+
   test("writes supervised worker stdout and stderr to daemon.log", async () => {
     const result = await runSupervisorFixture({
       workerSource: `