Merge pull request #234 from Lint111/feat/ai-checker-stderr

fix(ai-checker): keep CLI stderr out of the verdict and surface it on failure

src/ai-checker-base.ts

@@ -135,6 +135,7 @@ export abstract class AiCheckerBase<
   // Active check state
   protected checkMuxName: string | null = null;
   protected checkTempFile: string | null = null;
+  protected checkStderrFile: string | null = null;
   protected checkPromptFile: string | null = null;
   protected checkPollTimer: NodeJS.Timeout | null = null;
   protected checkTimeoutTimer: NodeJS.Timeout | null = null;
@@ -376,6 +377,7 @@ export abstract class AiCheckerBase<
     const shortId = this.sessionId.slice(0, 8);
     const timestamp = Date.now();
     this.checkTempFile = join(tmpdir(), `${this.tempFilePrefix}-${shortId}-${timestamp}.txt`);
+    this.checkStderrFile = join(tmpdir(), `${this.tempFilePrefix}-stderr-${shortId}-${timestamp}.txt`);
     this.checkPromptFile = join(tmpdir(), `${this.tempFilePrefix}-prompt-${shortId}-${timestamp}.txt`);
     this.checkMuxName = `${this.muxNamePrefix}${shortId}`;
 
@@ -386,6 +388,7 @@ export abstract class AiCheckerBase<
 
     // Ensure output temp file exists (empty) so we can poll it
     writeFileSync(this.checkTempFile, '');
+    writeFileSync(this.checkStderrFile, '');
 
     // Write prompt to file to avoid E2BIG error (argument list too long)
     // The prompt can be 16KB+ which exceeds shell argument limits
@@ -396,7 +399,7 @@ export abstract class AiCheckerBase<
     const modelArg = `--model "${this.config.model.replace(/"/g, '\\"')}"`;
     const augmentedPath = getAugmentedPath();
     const claudeCmd = `cat "${this.checkPromptFile}" | claude -p ${modelArg} --output-format text`;
-    const fullCmd = `export PATH="${augmentedPath}"; ${claudeCmd} > "${this.checkTempFile}" 2>&1; echo "${this.doneMarker}" >> "${this.checkTempFile}"; rm -f "${this.checkPromptFile}"`;
+    const fullCmd = `export PATH="${augmentedPath}"; ${claudeCmd} > "${this.checkTempFile}" 2> "${this.checkStderrFile}"; echo "${this.doneMarker}" >> "${this.checkTempFile}"; rm -f "${this.checkPromptFile}"`;
 
     // Spawn tmux session
     try {
@@ -461,18 +464,32 @@ export abstract class AiCheckerBase<
     const output = content.replace(this.doneMarker, '').trim();
 
     if (!output) {
-      return this.createErrorResult(`Empty output from ${this.checkDescription}`, durationMs);
+      const stderr = this.readStderrDiagnostic();
+      const detail = stderr ? `: ${stderr}` : '';
+      return this.createErrorResult(`Empty output from ${this.checkDescription}${detail}`, durationMs);
     }
 
     // Delegate to subclass for verdict parsing
     const parsed = this.parseVerdict(output);
     if (!parsed) {
-      return this.createErrorResult(`Could not parse verdict from: "${output.substring(0, 100)}"`, durationMs);
+      const stderr = this.readStderrDiagnostic();
+      const detail = stderr ? `; stderr: "${stderr}"` : '';
+      return this.createErrorResult(`Could not parse verdict from: "${output.substring(0, 100)}"${detail}`, durationMs);
     }
 
     return this.createResult(parsed.verdict, parsed.reasoning, durationMs);
   }
 
+  private readStderrDiagnostic(): string {
+    if (!this.checkStderrFile || !existsSync(this.checkStderrFile)) return '';
+
+    try {
+      return readFileSync(this.checkStderrFile, 'utf-8').trim().substring(0, 200);
+    } catch {
+      return '';
+    }
+  }
+
   private cleanupCheck(): void {
     // Clear poll timer
     if (this.checkPollTimer) {
@@ -509,6 +526,17 @@ export abstract class AiCheckerBase<
       this.checkTempFile = null;
     }
 
+    if (this.checkStderrFile) {
+      try {
+        if (existsSync(this.checkStderrFile)) {
+          unlinkSync(this.checkStderrFile);
+        }
+      } catch {
+        // Best effort cleanup
+      }
+      this.checkStderrFile = null;
+    }
+
     if (this.checkPromptFile) {
       try {
         if (existsSync(this.checkPromptFile)) {

test/ai-idle-checker.test.ts

@@ -71,7 +71,8 @@ describe('AiIdleChecker', () => {
   describe('Output Parsing', () => {
     it('should parse IDLE verdict', async () => {
       // Set up mock to return IDLE result after polling
-      mockedReadFileSync.mockReturnValueOnce('') // writeFileSync creates empty file
+      mockedReadFileSync
+        .mockReturnValueOnce('') // writeFileSync creates empty file
         .mockReturnValueOnce('IDLE\nSession shows completion message and prompt.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('some terminal output');
@@ -87,7 +88,8 @@ describe('AiIdleChecker', () => {
     });
 
     it('should parse WORKING verdict', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync
+        .mockReturnValueOnce('')
         .mockReturnValueOnce('WORKING\nSpinner characters detected, still processing.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('some terminal output');
@@ -100,8 +102,7 @@ describe('AiIdleChecker', () => {
     });
 
     it('should handle lowercase verdict', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('idle\nDone.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('idle\nDone.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(500);
@@ -112,7 +113,8 @@ describe('AiIdleChecker', () => {
     });
 
     it('should return ERROR for unparseable output', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync
+        .mockReturnValueOnce('')
         .mockReturnValueOnce('Something unexpected happened.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
@@ -125,8 +127,7 @@ describe('AiIdleChecker', () => {
     });
 
     it('should return ERROR for empty output', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('__AICHECK_DONE__');
-        .mockReturnValueOnce('__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(500);
@@ -175,10 +176,34 @@ describe('AiIdleChecker', () => {
       await vi.advanceTimersByTimeAsync(500);
       await checkPromise;
 
-      expect(mockedWriteFileSync).toHaveBeenCalledWith(
+      expect(mockedWriteFileSync).toHaveBeenCalledWith(expect.stringContaining('codeman-aicheck-'), '');
-        expect.stringContaining('codeman-aicheck-'),
+    });
-        ''
+
+    it('should keep Claude stderr separate from verdict output', async () => {
+      mockedReadFileSync.mockReturnValue('IDLE\n__AICHECK_DONE__');
+
+      const checkPromise = checker.check('output');
+      await vi.advanceTimersByTimeAsync(500);
+      await checkPromise;
+
+      const spawnArgs = mockedSpawn.mock.calls[0]?.[1];
+      const command = spawnArgs?.[spawnArgs.length - 1];
+      expect(command).toEqual(expect.any(String));
+      expect(command).toContain(' 2> "');
+      expect(command).not.toContain('2>&1');
+    });
+
+    it('should include Claude stderr when no verdict is produced', async () => {
+      mockedReadFileSync.mockImplementation((path) =>
+        String(path).includes('-stderr-') ? 'Claude CLI failed to load settings' : '__AICHECK_DONE__'
       );
+
+      const checkPromise = checker.check('output');
+      await vi.advanceTimersByTimeAsync(500);
+
+      const result = await checkPromise;
+      expect(result.verdict).toBe('ERROR');
+      expect(result.reasoning).toContain('Claude CLI failed to load settings');
     });
   });
 
@@ -223,7 +248,7 @@ describe('AiIdleChecker', () => {
 
       // Should have tried to kill the tmux session (initial kill + cleanup kill)
       const killCalls = mockedExecSync.mock.calls.filter(
-        call => typeof call[0] === 'string' && call[0].includes('kill-session')
+        (call) => typeof call[0] === 'string' && call[0].includes('kill-session')
       );
       expect(killCalls.length).toBeGreaterThan(0);
     });
@@ -236,8 +261,7 @@ describe('AiIdleChecker', () => {
 
   describe('Cooldown', () => {
     it('should start cooldown after WORKING verdict', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('WORKING\nStill processing.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('WORKING\nStill processing.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(500);
@@ -250,8 +274,7 @@ describe('AiIdleChecker', () => {
     });
 
     it('should return to ready after cooldown expires', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
@@ -267,8 +290,7 @@ describe('AiIdleChecker', () => {
     });
 
     it('should not start new check during cooldown', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
 
       const firstCheck = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
@@ -283,8 +305,7 @@ describe('AiIdleChecker', () => {
 
   describe('Error Handling', () => {
     it('should start error cooldown after parse error', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('garbage output\n__AICHECK_DONE__');
-        .mockReturnValueOnce('garbage output\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
@@ -302,8 +323,7 @@ describe('AiIdleChecker', () => {
       const cooldowns = [1100, 2100]; // Wait slightly longer than each cooldown
 
       for (let i = 0; i < 3; i++) {
-        mockedReadFileSync.mockReturnValueOnce('')
+        mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('garbage\n__AICHECK_DONE__');
-          .mockReturnValueOnce('garbage\n__AICHECK_DONE__');
 
         const checkPromise = checker.check('output');
         await vi.advanceTimersByTimeAsync(1000);
@@ -321,8 +341,7 @@ describe('AiIdleChecker', () => {
 
     it('should reset error counter on successful check', async () => {
       // First check: error
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('garbage\n__AICHECK_DONE__');
-        .mockReturnValueOnce('garbage\n__AICHECK_DONE__');
       const firstCheck = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
       await firstCheck;
@@ -332,8 +351,7 @@ describe('AiIdleChecker', () => {
       await vi.advanceTimersByTimeAsync(1100);
 
       // Second check: success
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('IDLE\nDone.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('IDLE\nDone.\n__AICHECK_DONE__');
       const secondCheck = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
       await secondCheck;
@@ -352,8 +370,7 @@ describe('AiIdleChecker', () => {
 
   describe('Buffer Handling', () => {
     it('should strip ANSI codes from terminal buffer', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('IDLE\n__AICHECK_DONE__');
-        .mockReturnValueOnce('IDLE\n__AICHECK_DONE__');
 
       const ansiBuffer = '\x1b[1mBold\x1b[0m \x1b[32mGreen\x1b[0m text';
       const checkPromise = checker.check(ansiBuffer);
@@ -365,8 +382,7 @@ describe('AiIdleChecker', () => {
     });
 
     it('should trim buffer to maxContextChars', async () => {
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('IDLE\n__AICHECK_DONE__');
-        .mockReturnValueOnce('IDLE\n__AICHECK_DONE__');
 
       // Create buffer longer than maxContextChars (1000)
       const longBuffer = 'x'.repeat(2000);
@@ -402,8 +418,7 @@ describe('AiIdleChecker', () => {
   describe('Reset', () => {
     it('should clear all state on reset', async () => {
       // Trigger a WORKING verdict to set state
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
@@ -440,24 +455,24 @@ describe('AiIdleChecker', () => {
       const handler = vi.fn();
       checker.on('checkCompleted', handler);
 
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('IDLE\nAll done.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('IDLE\nAll done.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
       await checkPromise;
 
-      expect(handler).toHaveBeenCalledWith(expect.objectContaining({
+      expect(handler).toHaveBeenCalledWith(
-        verdict: 'IDLE',
+        expect.objectContaining({
-      }));
+          verdict: 'IDLE',
+        })
+      );
     });
 
     it('should emit cooldownStarted event after WORKING', async () => {
       const handler = vi.fn();
       checker.on('cooldownStarted', handler);
 
-      mockedReadFileSync.mockReturnValueOnce('')
+      mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
-        .mockReturnValueOnce('WORKING\nBusy.\n__AICHECK_DONE__');
 
       const checkPromise = checker.check('output');
       await vi.advanceTimersByTimeAsync(1000);
@@ -477,8 +492,7 @@ describe('AiIdleChecker', () => {
       const cooldowns = [1100, 2100]; // Wait longer than exponential backoff
 
       for (let i = 0; i < 3; i++) {
-        mockedReadFileSync.mockReturnValueOnce('')
+        mockedReadFileSync.mockReturnValueOnce('').mockReturnValueOnce('garbage\n__AICHECK_DONE__');
-          .mockReturnValueOnce('garbage\n__AICHECK_DONE__');
         const checkPromise = checker.check('output');
         await vi.advanceTimersByTimeAsync(1000);
         await checkPromise;